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854146
SL 750 SHIVER
SL 750 SHIVER
THE VALUE OF SERVICE Thanks to continuous technical updates and specific training programs on aprilia products, only aprilia Official Network mechanics know this vehicle fully and have the special tools necessary to carry out maintenance and repair operations correctly. The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding, its regular maintenance and the use of Original aprilia Spare Parts only are essential factors! For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or search directly on the inset map in our Official Website: www.aprilia.com Only aprilia Original Spare Parts ensure products already studied and tested during the vehicle design stage. All aprilia Original Spare Parts undergo quality control procedures to guarantee full reliability and duration. The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this manual remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions shown in this publication are available in all countries. The availability of individual versions should be confirmed with the official aprilia sales network. Copyright 2007- aprilia. All rights reserved. Reproduction of this publication in whole or in part is prohibited. aprilia - After sales service. aprilia trademark is property of Piaggio & C. S.p.A.
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS SPECIAL TOOLS MAINTENANCE TROUBLESHOOTING ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE POWER SUPPLY SUSPENSIONS CHASSIS BRAKING SYSTEM CLUTCH SYSTEM COOLING SYSTEM BODYWORK
CHAR S-TOOLS MAIN TROUBL ELE SYS ENG VE ENG P SUPP SUSP CHAS BRAK SYS CLU SYS COOL SYS BODYW
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Characteristics
SL 750 SHIVER
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH. Fuel
CAUTION
FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE. DO NOT DISPERSE FUEL IN THE ENVIRONMENT. KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been shut off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down. Coolant The coolant contains ethylene glycol which, under certain conditions, can become flammable. When it burns, ethylene glycol produces an invisible flame which however can cause burns.
CAUTION
PAY ATTENTION NOT TO POUR COOLANT ON HOT ENGINE OR EXHAUST SYSTEM COMPONENTS; IT MAY CATCH FIRE PRODUCING INVISIBLE FLAMES. IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE. EVEN IF IT IS TOXIC, THE COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS THEY MAY DRINK IT. CHAR - 2
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KEEP OUT OF THE REACH OF CHILDREN DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE. ENGINE OR TRANSMISSION OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS. WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL. HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Brake and clutch fluid
THE BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE. KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID, IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IF THE ELECTROLYTIC FLUID COMES INTO CONTACT WITH THE SKIN, RINSE WELL WITH ABUNDANT FRESH WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS INTO CONTACT WITH YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETABLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY. KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION CHAR - 3
Characteristics
SL 750 SHIVER
When repairing, dismantling and reassembling the vehicle follow the recommendations reported below carefully. BEFORE DISASSEMBLING COMPONENTS Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle. Use the special tools designed for this bike, as required. COMPONENTS REMOVAL Do not loosen and/or tighten screws and nuts using pliers or other tools other than the especially designed wrench. Mark positions on all connection joints (pipes, cables, etc.) before separating them, and identify them with distinctive symbols. Each component needs to be clearly marked in order to be identified during assembly. Clean and wash the removed components carefully using a low-flammability detergent. Keep coupled parts together since they have "adjusted" to each other due to normal wear and tear. Some components must be used together or replaced altogether. Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY NEED REPLACING. Only use ORIGINAL APRILIA SPARE PARTS. Comply with lubricant and consumables usage guidelines. Lubricate parts (whenever possible) before reassembling them. When tightening nuts and screws, start from the ones with the largest section or from the internal ones, moving diagonally. Tighten nuts and screws in successive steps before applying the tightening torque. Always replace self-locking nuts, washers, sealing rings, circlips, O-rings, split pins and screws with new ones if their tread is damaged. When fitting bearings, make sure to lubricate them well. Check that each component is fitted correctly. After a repair or routine maintenance procedure, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic density. Clean all junction surfaces, oil guard rims and washers before refitting them. Smear a light layer of lithium-based grease on the oil guard rims. Reassemble the oil guard and the bearings with the brand or lot number facing outward (visible side). ELECTRIC CONNECTORS Electric connectors must be disconnected as described below as non-compliance with the procedure so described causes irreparable damage to both the connector and the cable harness: CHAR - 4
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Press the relevant safety hooks, if any. Grip the two connectors and disconnect them by pulling them in opposite directions. If there are signs of dirt, rust, humidity, etc., clean the connector internal parts carefully using a pressurised air jet. Make sure that the cables are correctly linked to the connector internal terminal ends. Then insert the two connectors making sure that they couple correctly (if the relevant hooks are provided, you will hear them "click" into place).
CAUTION
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY ROUND. TIGHTENING TORQUE
CAUTION
DO NOT FORGET THAT THE TIGHTENING TORQUE OF ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE TIGHTENING TORQUE OF FASTENING PARTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.
Running-in
Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients are ideal to run in engine, brakes and suspensions effectively. Vary your driving speed during run-in. In this way, you allow for the work of components to be "loaded" and then "unloaded", thus cooling engine parts.
CAUTION
ONLY AFTER THE SERVICE AT THE END OF THE RUN-IN PERIOD CAN THE BEST PERFORMANCE OF YOUR VEHICLE BE OBTAINED. Follow the guidelines detailed below: Do not twist the throttle grip abruptly and completely when the engine is working at a low revs, either during or after run-in. During the first 100 km (62 miles) operate the brakes with caution, avoid rough and long braking. That is to permit the adequate adjustment of the pad friction material to the brake discs.
AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official aprilia Dealer FOR THE CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE SECTION, TO AVOID INJURING YOURSELF, OTHERS AND/OR DAMAGING THE VEHICLE.
CHAR - 5
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Vehicle identification
Write down the chassis and engine number in the specific space of this booklet. The chassis number is handy when purchasing spare parts.
CAUTION
ALTERING IDENTIFICATION NUMBERS IS AN OFFENCE WHICH CAN RESULT IN SEVERE CRIMINAL AND ADMINISTRATIVE CHARGES. PARTICULARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WARRANTY. This number is composed by numbers and letters, as in the example shown below. ZD4RA0000YSXXXXXX KEY: ZD4: WMI (World manufacturer identifier) code; RA: model; 000: version variation; 0: digit free Y year of manufacture S: production plant (S= Scorz); XXXXXX: progressive number (6 digits); ENGINE NUMBER The engine number is printed on the base of the left side engine crankcase. Engine No. ....................
CHASSIS NUMBER The chassis number is stamped on the right side of the headstock. Chassis No. ....................
SL 750 SHIVER
Characteristics
Engine
ENGINE
Specification Model Type Cylinder quantity Overall engine capacity Bore / stroke Valve clearance at intake Outlet valve clearance Compression ratio Start-up Engine revs at idle speed Clutch Lubrication system Air filter Cooling Desc./Quantity M551M 90 longitudinal V-twin, 4-stroke, 4 valves per cylinder, 2 overhead camshafts. 2 749.9 cm (45.76 cu.in) 92 x 56.4 mm (3.62 x 2.22 cu.in) 0.11 - 0.18 mm (0.0043 - 0.0071 in) 0.16 - 0.23 mm (0.0063 - 0.0091 in) 11.0: 1 electric 1400 100 rpm Multiple-disk, oil-bathed clutch with control on the left side of the handlebar Wet crankcase. Pressure system regulated by trochoidal pump with dry cartridge filter Fluid
GEAR
Specification Type Desc./Quantity Mechanical, 6 speeds with foot lever on the lefthand side of the engine
Transmission
GEAR RATIOS
Specification Gear ratio 1st gear ratio 2nd gear ratio 3rd gear ratio 4th gear ratio 5th gear ratio 6th gear ratio Final drive gear ratio Desc./Quantity Gear primary drive 38/71 14/36 (secondary) 17/32 (secondary) 20/30 (secondary) 22/28 (secondary) 23/26 (secondary) 24/25 (secondary) 16/44
Capacities
CAPACITY
Specification Fuel (reserve included) Fuel reserve Desc./Quantity 15 l (3.30 UKgal; 3.96 USgal) 3 l (0.66 UKgal; 0.79 USgal) CHAR - 7
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Fork oil quantity (for each stem): Coolant Seats Vehicle max. load
Desc./Quantity 3.0 l (without oil filter change) (0.66 UKgal; 0.79 USgal) 3.2 l (without oil filter change) (0.70 UKgal; 0.85 USgal) 535 cm (32.65 cu.in) 1.8 l (0.40 UKgal; 0.48 USgal) 2 190 kg (418.9 lb) (Rider + passenger + luggage)
Drive chain
DRIVE CHAIN
Specification Type Model Desc./Quantity Endless (without master link) and with sealed links. No. of links 108 525 ZRPK
Electrical system
ELECTRICAL SYSTEM
Specification Battery Main fuses Auxiliary fuses (Permanent magnet) Generator Desc./Quantity 12V - 10 Ah 30A 3A, 10A, 15A, 20A 13.5 V - 450 W at 6000 rpm
SPARK PLUGS
Specification Standard spark plugs Spark plug electrode gap Resistance Desc./Quantity NGK CR7EKB 0.6 0.7 mm (0.024 0.028 in) 5 kOhm
BULBS
Specification Low-beam light High-beam light Front tail light Turn indicator lights License plate light Rear tail light / stop light Rpm indicator lighting Multifunction display lighting Desc./Quantity 12 V - 55 W H7 12 V - 55 W H7 12V - 5W x 2 12V - 10W 12V - 5W 12V - 5/21W x 2 LED LED
WARNING LIGHTS
Specification High-beam light Right turn indicator Left turn indicator General warning Gear in neutral CHAR - 8 Desc./Quantity LED LED LED LED LED
SL 750 SHIVER
Characteristics
Desc./Quantity Upside-down hydraulic action telescopic fork, 43 mm (1.69 in) stems 120 mm (4.72 in) Oscillating swingarm and single adjustable hydraulic shock absorber 122 mm (4.80 in)
SIZES A AND B
Specification Size A Size B Desc./Quantity 658.5 mm (25.93 in) 373.4 mm (14.70 in)
Brakes
BRAKES
Specification Front
Rear
Desc./Quantity Double floating disc, 320 mm (12.60 in), radiallymounted callipers with four plungers- two of them 27 mm (1.06 in), the other two 32.03 (1.26 in) and 4 pads 240 mm (9.45 in) disc brake, 35 mm (1.38 in) twin-plunger calliper
CHAR - 9
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TYRES
Specification Tyre type (standard) Front Inflation pressure Rear Inflation pressure Desc./Quantity DUNLOP SPORTMAX QUALIFIER - METZELER M3 120/70 ZR17" (58W) 1 passenger: 2.3 bar (230 kPa) (33.36 PSI) 2 passengers: 2.5 bar (250 kPa) (36.26 PSI) 180/55 ZR17" (73W) or 190/50 ZR17" (73W) 1 passenger: 2.5 bar (250 kPa) (36.26 PSI) 2 passengers: 2.8 bar (280 kPa) (40.61 PSI)
Supply
FUEL SUPPLY SYSTEM
Specification Type Throttle valves diameter Fuel Desc./Quantity Electronic injection (Multipoint) 52 mm (2.05 in) Premium unleaded petrol, minimum octane rating of 95 (NORM) and 85 (NOMM)
Tightening Torques
FRAME ASSEMBLY
Name TCEI screw fixing Shock Absorber Counterplate to right chassis bracket - M10x30 (1) TCEI screw fixing Fairings to engine - M12x282 (3) Self-tapping nut fixing left Fairing to engine and Framework to chassis fairings - M12 (7) TC TORX screw fixing Perimeter frame to the chassis fairings - M12x53 (4) TCEI upper screw fixing Saddle pillar to chassis M8x30 (2) TCEI lower screw fixing Saddle pillar to chassis M8x40 (2) Lower self-tapping nut fixing Saddle pillar to chassis - M8 (2) TCEI screw fixing lambda probe plate to right-side chassis (pre-fit on right fairing - M4x10 (2) Torque in Nm 50 Nm (36.88 lbf ft) 80 Nm (59 lbf ft) 80 Nm (59 lbf ft) 80 Nm (59 lbf ft) 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) 3 Nm (2.3 lbf ft)
CHAR - 10
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FOOTREST UNIT
Name TCEI sunken screw fixing Footrest Support to chassis - M8x30 (6) Non-slip bolt (fit on driver footrest) - M8 (2) Self-tapping TE screw for Footrest finish - M6x12 (8) Torque in Nm 18 Nm (13.27 lbf ft) 25 Nm (18.44 lbf ft) 10 Nm (7.37 lbf ft)
STAND UNIT
Name Screw for Stand - M10x1.25 (1) Lower nut - M10x1.25 (1) Self-tapping TE screw fixing Stand Plate on engine - M8x30 (3) Torque in Nm 10 Nm (10.34 lbf ft) 30 Nm (22.13 lbf ft) 25 Nm (18.44 lbf ft)
SWINGARM UNIT
Name TCEI screw Swing Arms coupling - M8x70 (7) Swingarm Pin adjustment Bushing (1) Swingarm Pin Ring Nut (1) Chain tensioner set screw (2) SERPRESS nut (on chain tensioner pad set screw) - M8 (2) TPSI screw fixing rear stand bushing - M6x40 (2) TBEI screw fixing chain tensioner pad - M5x12 (3) Self-tapping TBEI screw fixing chain guard, brake pipe protection and counterslider - M5x9 (5) Calliper support lock pin - M12 (1) Torque in Nm 25 Nm (18.44 lbf ft) 12 Nm (8.85 lbf ft) 60 Nm (44.25 lbf ft) 10 Nm (7.37 lbf ft) 3 Nm (2.21 lbf ft) 4 Nm (2.95 lbf ft) 50 Nm (36.88 lbf ft) - Loctite 243
CHAR - 11
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SL 750 SHIVER
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CHAR - 13
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TANK UNIT
Name Self-locking nut - M5 (6) Self-tapping TE screw - M6x30 (2) Torque in Nm 6 Nm (4.42 lbf ft) 6 Nm (4.42 lbf ft)
25 Nm (18.44 lbf ft) 3 Nm (2.21 lbf ft) 3 Nm (2.21 lbf ft) 4 Nm (2.95 lbf ft) 5 Nm (3.69 lbf ft) 3 Nm (2.21 lbf ft) 7 Nm (5.16 lbf ft)
ENGINE UNIT
Name TCEI screw fixing Pin to gearbox lever and Gearbox Lever to knurled shaft- M6x16 (2) Left lock nut for ball joint - M6 (1) Lock nut for ball joint - M6 (1) Pin fixing screw (2) Countersunk screw fixing pin (1) Brake pipe union fixing pipe to pump - M10x1 (1) Filler with bleed (Heng Tong) fixing pipe to pin M10x1 (1) Self-tapping TE screw fixing Pinion - M10x1.25x55 (1) Torque in Nm 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) 50 Nm (36.88 lbf ft) - Loctite 243
COMPLETE HEAD
Name Cam cap/head fixing screws - M6 (16) Torque in Nm Pre-tightening: (4.90 - 6.86) Nm ((3.61 - 5.06) lbf ft) Tightening: (9.81 - 12.75) Nm ((7.24 - 9.40) lbf ft)
CHAR - 14
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Name Map sensor fitting (brass) (2) Map sensor fitting (steel) (2) H20 Bleed fitting (brass) (1) H20 Bleed fitting (steel) (1) Cap - M6 (1) Oil cap - M10x1.25 (2) Screw fixing fitting to bleed - M5 (4) Special screw fixing Head Cover - M6 (8) H20 Temperature sensor - M12x1.5 (1) Water sensor housing threaded cap - M12x1.5 (1) Nut fixing Stud Bolts to Head - M10x1.25 (8)
Torque in Nm 2 Nm (1.48 lbf ft) (Loctite 243) 3.50 Nm (2.58 lbf ft) (Loctite 243) 2 Nm (1.48 lbf ft) (Loctite 243) 3.50 Nm (2.58 lbf ft) (Loctite 243) To fit flush 7 Nm (5.16 lbf ft) (3M SCOTCH GRIP 2353) 5.50 Nm (4.06 lbf ft) 8 Nm (5.90 lbf ft) 23 Nm (16.96 lbf ft) 10 Nm (7.38 lbf ft) (Loctite Drise AL 506) Pre-torque 10 Nm (7.38 lbf ft) - Torque 13 Nm (9.59 lbf ft) + 90 + 90 (Lubricate threads before tightening) Head / Cylinder / Crankcase internal side retainer 12 Nm (8.85 lbf ft) - M6 (4) Head / Cylinder / crankcase external side retainer 12 Nm (8.85 lbf ft) - M6 (2) Nut fixing Stud Bolts to Head - M6 (4) 12 Nm (8.85 lbf ft) Nut fixing Stud Bolts to Head - M8 (2) 26 Nm (19.18 lbf ft) Spark plug (2) 13 Nm (9.59 lbf ft) Screw fixing Pencil to Eldor coil - M6 (2) 5.50 Nm (4.06 lbf ft) Screw fixing camshaft retaining plate - torx M3 (8) 3 Nm (2.21 lbf ft) (Loctite 270) Camshaft locking threaded cap 11 Nm (8.11 lbf ft)
TIMING SYSTEM
Name Nut fixing camshaft gears (pre-tightening) - M15x1 (4) Nut fixing camshaft gears - M15x1 (4) Screw fixing Timing system Gear - M24x1.5 (2) Special screw fixing Mobile / Fixed Pads - M8 (4) Chain tensioner fixing screw - M6 (4) Cylinder Plate fixing screw - M6 (4) Screw for Chain tensioner adjustment - M6 (2) Torque in Nm 30 Nm (22.13 lbf ft) 90 Nm (66.38 lbf ft) 40 Nm (29.50 lbf ft) (3M SCOTCH GRIP 2353) 19 Nm (14.01 lbf ft) (Loctite 242) 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 5.50 Nm (4.06 lbf ft)
CHAR - 15
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SL 750 SHIVER
Name Screw fixing Gear locking pawl - M6 (1) Screw fixing Desmodromic / Sprocket Selector M8 (1) Selector Plate fixing screw - M5 (3) Selector pin retainer on clutch side crankcase half - M10x1.5 (1) Screw fixing clutch / flywheel side crankcase half - M6 (8) Screw fixing clutch / flywheel side crankcase half - M8 (9) Oil sensor retainer on clutch side crankcase half (1) Suction rose fixing screw (2) Oil Filter fitting retainer on clutch side crankcase half (1) Oil filter (1) Screw fixing bearing retainer - M6 (3)
Torque in Nm 12 Nm (8.85 lbf ft) 23 Nm (16.96 lbf ft) 5.50 Nm (4.06 lbf ft) 16 Nm (11.80 lbf ft) 12 Nm (8.85 lbf ft) 26 Nm (19.18 lbf ft) 13 Nm (9.59 lbf ft) 12 Nm (8.85 lbf ft) 20 Nm (14.75 lbf ft) 14 Nm (10.33 lbf ft) 10 Nm (7.38 lbf ft) (Loctite 270)
SL 750 SHIVER
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Name Screw fixing engine Bracket / clutch side crankcase half - M6 (2) Crankshaft access cover (1) H20 Pump Rotor (1) Screw fixing Stick-coil / Head cover - M6 (2) Screw fixing plate / "split" clutch cover - M4 steel A2 (6)
Torque in Nm 12 Nm (8.85 lbf ft) 4 Nm (2.95 lbf ft) 4.50 Nm (3.32 lbf ft) 5.50 Nm (4.06 lbf ft) 3 Nm (2.21 lbf ft) (Loctite 243)
CHAR - 17
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CHAR - 18
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There are two types of crankshaft for each bearing: 4 - 5 for flywheel side; 7 - 8 for clutch side.
THE SHAFT MAY HAVE TWO DIFFERENT CLASSES ON THE TWO BEARINGS.
choose the bushings to be used for coupling according to the following table.
MAIN BUSHINGS
Specification Main journal type 4 (flywheel side) Main journal type 4 (flywheel side) Main journal type 5 (flywheel side) Main journal type 5 (flywheel side) Main journal type 7 (clutch side) Main journal type 7 (clutch side) Main journal type 8 (clutch side) Main journal type 8 (clutch side) Crankcase category Crankcase can be selected from two types (A or B) according to the centre to centre distance between the primary reduction gears. The category can be checked out on clutch-side crankcase half, at the back.
NOTE
Desc./Quantity crankcase type 1 - half-bushings A (red) crankcase type 2 - half-bushings B (blue) crankcase type 1 - half-bushings B (blue) crankcase type 2 - half-bushings C (yellow) crankcase type 1 - half-bushings A (red) crankcase type 2 - half-bushings B (blue) crankcase type 1 - half-bushings B (blue) crankcase type 2 - half-bushings C (yellow)
SHOULD THE CRANKCASE BE REPLACED, THIS IS SUPPLIED WITH THE PRIMARY REDUCTION GEAR ALREADY COUPLED.
CHAR - 19
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Crankshaft category Shaft can be selected from two types (1 or 2) according to the crank pin diameter. Shaft can be selected from seven types (E1, E2, ...) according to connecting rod weight.
BUSHINGS
Specification Crankshaft type 1 Crankshaft type 2 Connecting rod selection Not all weight types are available as spare parts; only the main two. Refer to the following table for your choice: Desc./Quantity Connecting rod type 1: half-bushings A (red) Connecting rod type 1: half-bushings B (blue)
CHAR - 20
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CONNECTING RODS
Specification Type E1 crankshaft Type E2 crankshaft Type E3 crankshaft Type E4 crankshaft Type E5 crankshaft Type E6 crankshaft Type E7 crankshaft
CAUTION
Desc./Quantity Original connecting rod type: brown Spare connecting rod type: brown Original connecting rod type: blue Spare connecting rod type: blue Original connecting rod type: yellow Spare connecting rod type: yellow Original connecting rod type: green Spare connecting rod type: green Original connecting rod type: pink Spare connecting rod type: pink Original connecting rod type: black Spare connecting rod type: black Original connecting rod type: white Spare connecting rod type: white
THE CONNECTING RODS OF THE SAME CRANKSHAFT MUST BE THE SAME COLOUR AND HAVE THE SAME TYPE OF COUPLING AS THE CRANKSHAFT. UPON REFITTING, MAKE SURE THAT THE HALF-BUSHINGS ARE OF THE SAME TYPE.
See also
Removing the clutch cover Removing the flywheel cover
AGIP CHAIN GREASE SPRAY Recommended CHAIN oil AGIP BRAKE 4 / BRAKE 5.1 Recommended BRAKE FLUID AGIP BRAKE 4 / BRAKE 5.1 Recommended CLUTCH FLUID SPECIAL AGIP PERMANENT Recommended ENGINE COOLfluid ANT
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CHAR - 22
INDEX OF TOPICS
SPECIAL TOOLS
S-TOOLS
Special tools
SL 750 SHIVER
SPECIAL TOOLS
Stores code 020709Y Description Engine support
020710Y
Engine plate
AP8140187
020711Y
020712Y
020713Y
Flywheel extractor
S-TOOLS - 2
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Special tools
020715Y
9100896
020716Y
020717Y
AP8140302
S-TOOLS - 3
Special tools
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020719Y
Timing pin
020720Y
Timing tool
AP8140179
020721Y
020722Y
020376Y
Punch adaptor
S-TOOLS - 4
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Special tools
020412Y
020439Y
020263Y
020365Y
020364Y
S-TOOLS - 5
Special tools
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Description 30 mm punch
020441Y
020358Y
37 x 40 mm punch
020357Y
32 x 35 mm adaptor
020359Y
42 x 47 mm punch
020360Y
52 x 55 mm punch
S-TOOLS - 6
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Special tools
020724Y
020725Y
020726Y
020727Y
8140180
S-TOOLS - 7
Special tools
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8140199
Tool panel
8202222
8140426
XXXXXXX
S-TOOLS - 8
INDEX OF TOPICS
MAINTENANCE
MAIN
Maintenance
SL 750 SHIVER
Maintenance chart
Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, aprilia offers a set of checks and maintenance services (at the owner's expense) that are summarised in the table shown on the following page. Any minor faults should be reported without delay to an Authorised aprilia Dealer or Sub-Dealer without waiting until the next scheduled service to solve it. All scheduled maintenance services must be carried out at the specified times and kilometres, even if the stated mileage has not yet been reached. Carrying out scheduled services on time is essential to ensure your warranty remains valid. For further information regarding Warranty procedures and ''Scheduled Maintenance'', please refer to the ''Warranty Booklet''.
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING APPLICATIONS.
AT EVERY START-UP
Action Warning light indicating error on the instrument panel - check
MAIN - 2
SL 750 SHIVER
Maintenance
EVERY 24 MONTHS
Action Clutch control fluid - Replace Brake fluid - Change Coolant - Change Fork oil - Change
MAIN - 3
Maintenance
SL 750 SHIVER
EVERY 4 YEARS
Action Fuel pipes - Replace
Spark plug
At regular intervals, remove the spark plug and clean off any carbon deposits or replace as required.
CAUTION
ALWAYS REPLACE BOTH SPARK PLUGS, EVEN IF ONLY ONE NEEDS REPLACING. Remove the saddle. Remove the side fairings.
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS, LEAVE THE ENGINE AND MUFFLER TO COOL OFF TO AMBIENT TEMPERATURE. FRONT SPARK PLUG Working on the left side of the vehicle, undo and remove the screw and collect the washer.
MAIN - 4
SL 750 SHIVER
Maintenance
Detach the radiator towards the vehicle right-hand side and lower it so as to be able to work on the coil.
MAIN - 5
Maintenance
SL 750 SHIVER
Remove at least one side air deflector. Slide off the key lock plate.
Undo and remove the two screws and collect the two collars. Undo and remove the chamber fixing screws. Slide off the "too full" and breather pipes from the chamber. Lift the tank by turning it on the hinge. Release the petrol pipe. Disconnect the pump cable harness. Working on the right side, unscrew and remove the nut and slide off the bolt from the left side.
MAIN - 6
SL 750 SHIVER
Maintenance
Lift the tank. Undo and remove the rear coil fixing screw.
Slide off the rear coil. Unscrew and slide off the rear spark plug.
Check the gap between the electrodes with a feeler thickness gauge.
CAUTION
The gap between the electrodes should be between 0.7 0.8 mm (0.027 0.031 in). Otherwise, replace the spark plug (2). Make sure the washer is in good conditions. Installation: Once the washer is fitted, screw the spark plug (2) carefully to avoid damaging the thread. Tighten using the spanner supplied in the tool kit. Make each spark plug (2)
MAIN - 7
Maintenance
SL 750 SHIVER
IT IS ESSENTIAL TO TIGHTEN THE SPARK PLUG (2) PROPERLY. A LOOSE SPARK PLUG MAY CAUSE ENGINE OVERHEATING AND RESULT IN SEVERE DAMAGE.
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING APPLICATIONS.
ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM. IF YOU CHECK LEVEL WHEN THE ENGINE IS COLD, OIL LEVEL COULD TEMPORARILY DROP BELOW THE "MIN" MARK. THIS SHOULD NOT BE CONSIDERED A PROBLEM PROVIDED THAT THE ALARM WARNING LIGHT AND THE ENGINE OIL PRESSURE ICON ON THE DISPLAY DO NOT TURN ON SIMULTANEOUSLY.
CAUTION
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER A TRIP OR AFTER TRAVELLING APPROXIMATELY 15 km (10 mi), OUT OF TOWN (ENOUGH TO WARM UP ENGINE OIL TO OPERATING TEMPERATURE). Shut off the engine. Keep the vehicle upright with the two wheels on the ground. Check the correct oil level through the appropriate sight glass on the engine crankcase. MAX = maximum level. MIN = minimum level The oil level is correct when it is close to the "MAX" reference.
MAIN - 8
SL 750 SHIVER
Maintenance
Replacement
Check the engine oil level frequently. To change the oil:
CAUTION
HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY; IDEAL TEMPERATURE IS REACHED AFTER THE ENGINE HAS RUN FOR ABOUT TWENTY MINUTES.
OIL BECOMES VERY HOT WHEN THE ENGINE IS HOT; BE CAREFUL NOT TO GET BURNED WHEN CARRYING OUT THE OPERATIONS DESCRIBED BELOW. Use a cloth to wipe off any mud deposit on the area next to the filler plug (1). Place a container with + 4000 cm (244 cu.in) capacity under the drainage plug (2). Unscrew and remove the drainage plug (2). Unscrew and remove the filler plug (1). Drain the oil into the container; allow several minutes for oil to drain out completely. Replace the sealing washer of the drainage plug (2). Remove any metal scrap attached to the drainage plug (2) magnet. Screw and tighten the drainage plug (2).
See also
Engine oil filter Check
Drain off the engine oil. Remove the oil filter. Fit a new engine oil filter. Add engine oil up to the correct level.
See also
MAIN - 9
Maintenance
SL 750 SHIVER
Replacement
Air filter
Remove the fuel tank. Disconnect the air temperature sensor.
MAIN - 10
SL 750 SHIVER
Maintenance
Working on both ducts, turn the upper part of the intake ducts anticlockwise and remove it.
COVER THE INTAKE DUCTS WITH A CLEAN CLOTH SO THAT FOREIGN BODIES DO NOT GET INTO THE INLET DUCTS. UPON REFITTING AND BEFORE PLACING THE FILTER CASING COVER, MAKE SURE NEITHER THE CLOTH NOR ANY OTHER OBJECT HAS BEEN LEFT INSIDE THE FILTER CASING. MAKE SURE THE FILTERING ELEMENT IS CORRECTLY PLACED SO THAT UNFILTERED AIR DOES NOT FLOW IN. DO NOT FORGET THAT EARLY WEAR OF THE PISTON RINGS AND THE CYLINDER CAN BE CAUSED BY A MALFUNCTIONING OR MISPLACED FILTERING ELEMENT. REFITTING Upon refitting, pay attention when inserting intake ducts and check that the bayonet joint is released once every duct has been inserted and rotated.
WHENEVER THE HEAD COVER IS REMOVED, ALL FOUR RUBBER RINGS AND THE GASKET SHOULD BE REPLACED.
MAIN - 11
Maintenance
SL 750 SHIVER
Using a thickness gauge, measure the distance between the tip of the crankshaft and the valve bowl.
If valve clearance is not within the tolerance range, adjust as follows: Take the engine to the TDC. Lock the camshafts by using the corresponding timing pins.
Specific tooling
020719Y Timing pin
Characteristic
Valve clearance at intake 0.11 - 0.18 mm (0.0043 - 0.0071 in) Outlet valve clearance 0.16 - 0.23 mm (0.0063 - 0.0091 in)
CAUTION
Remove one camshaft at a time Leave the other camshaft assembled and blocked by means of the timing pin.
IF BOTH CAMSHAFTS ARE REMOVED, THE ENGINE SPINS MAKING TIMING NECESSARY. Remove the bowl tappets and the adjustment shims using a magnet.
NOTE
GREASE THE BOWL TAPPETS AND THE ADJUSTMENT SHIMS PROPERLY EACH TIME THEY ARE REMOVED.
Replace calibrated pads with a pad thick enough to correct the valve clearance previously detected.
1. Calibrated pad 2.60 2. Calibrated pad 2.65 3. Calibrated pad 2.70 4. Calibrated pad 2.75 5. Calibrated pad 2.80 MAIN - 12
SL 750 SHIVER
Maintenance
6. Calibrated pad 2.85 7. Calibrated pad 2.90 8. Calibrated pad 2.95 9. Calibrated pad 3.00 10.Calibrated pad 3.05 11.Calibrated pad 3.10 12.Calibrated pad 3.15 13.Calibrated pad 3.20 14.Calibrated pad 3.25 15.Calibrated pad 3.30 16.Calibrated pad 3.35 17.Calibrated pad 3.40 18.Calibrated pad 2.55 19.Calibrated pad 2.50 20.Calibrated pad 2.45 21.Calibrated pad 2.40
CAUTION
BEFORE REFITTING HEAD COVERS, CLEAN HEAD AND COVER SURFACES CAREFULLY. Apply THREEBOND on the head cover perimeter along the gasket housing.
See also
Removing the head cover
MAIN - 13
Maintenance
SL 750 SHIVER
MAIN - 14
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Troubleshooting
SL 750 SHIVER
TROUBLESHOOTING PROCEDURE IF THE EFI WARNING LIGHT ON THE INSTRUMENT PANEL TURNS ON OR IF THERE IS ABNORMAL ENGINE PERFORMANCE
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. 1 - THE "EFI" WARNING LIGHT IS ON AND THE WORD "SERVICE" IS SHOWN or THE "EFI" WARNING LIGHT IS FLASHING AND THE WORDS "URGENT SERVICE" ARE SHOWN or ONE OF THE TWO SITUATIONS TAKES PLACE AND IS SUDDENLY OUT or THERE IS ABNORMAL ENGINE PERFORMANCE 2 - CONNECT TO THE CONTROL UNIT THROUGH AXONE (MINIMUM VERSION: 5.1.5) BY SELECTING "SELF- DIAGNOSIS, APRILIA, SL 750 SHIVER" 3 - ARE CURRENT "ATT" or STORED "MEM" ERRORS SHOWN IN THE "ERRORS DISPLAY" SCREEN PAGE? YES, go to 4; NO, go to 12. 4 - IF THE ERROR IN THE CENTRAL WINDOW IS SELECTED AND "?" IS DISPLAYED, PRESS THE KEY "?" TO OBTAIN FURTHER INFORMATION ABOUT THE ERROR. THEN GO TO THE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS" CHAPTER AND READ THE INFORMATION CONCERNING THE DEFECTIVE COMPONENT 5 - ACCORDING TO WHAT IS INDICATED ABOUT THE ERROR/S, PROCEED AS SUGGESTED AND SOLVE THE PROBLEM 6 - WAS THE PROBLEM SOLVED BY REPLACING THE MARELLI CONTROL UNIT? YES, go to 7; NO, go to 8. 7 - READ THE ACTIVATION PROCEDURE FOR A NEW CONTROL UNIT ON THE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/ECU/MARELLI CONTROL UNIT" CHAPTER - END 8 - SELECT "ERROR CLEARING" FROM THE "DEVICES ACTIVATION (INJECTOR)" SCREEN PAGE 9 - WAS THE PROBLEM SOLVED BY REPLACING THE THROTTLE GRIP SENSOR (DEMAND) OR THE THROTTLE BODY? NO, END; YES, go to 10 10 - READ THE RESET PROCEDURE ON THE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/THROTTLE GRIP POSITION SENSOR OR THROTTLE BODY" CHAPTER END 11 - CHECK IF THERE ARE CURRENT OR STORED ERRORS DETECTED BY THE INSTRUMENT PANEL REFERRING TO THE "DIAGNOSIS" CHAPTER, "INSTRUMENT
TROUBL - 2
SL 750 SHIVER
Troubleshooting
PANEL ERRORS" SECTION. IF THERE ARE ERRORS PRESENT, SOLVE THE FAILURE AND SELECT "CLEAR ERRORS"; IF THERE ARE NO ERRORS PRESENT, go to 12 12 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE "AIR TEMPERATURE" PARAMETER INDICATE A VALUE EQUIVALENT TO ROOM TEMPERATURE? YES, go to 13; NO, note A 13 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE ENGINE TEMPERATURE PARAMETER WITH COLD ENGINE INDICATE A VALUE SIMILAR TO THAT OF THE AIR TEMPERATURE PARAMETER? AFTER STARTING THE ENGINE, DOES THE PARAMETER INCREASE GRADUALLY INDICATING A CORRECT VALUE? YES, go to 14; NO, note B 14 - IN THE "ENGINE PARAMETER READING" AND THE "LAMBDA SENSOR CORRECTION" SCREEN PAGES, WITH ENGINE AT IDLE AND ENGINE TEMPERATURE AT > 90C, DOES THE VALUE VARY WITHIN THE 0.9 - 1.1 RANGE? YES, go to 15; NO, note C 15 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE AND WITH ENGINE AT IDLE, ARE "FRONT THROTTLE CORRECTION PARAMETERS" OR "REAR THROTTLE CORRECTION" WITHIN THE (-0.4 - +0.4) RANGE? AND IN THE SAME SCREEN PAGE, ARE THE "FRONT THROT., POT. 1 (DEGREES)" AND "REAR THROT., POT. 1 (DEGREES)" PARAMETERS > OR = TO 0.5 WITH ENGINE AT IDLE? CAUTION: THE DIFFERENCE OF THE THROTTLE CORRECTION VALUES BETWEEN THE REAR AND FRONT CYLINDER MUST NOT BE >0.4 YES, go to 16; NO, note D 16 - CHECK: ENGINE REVOLUTION SENSOR, FUEL PRESSURE, INJECTORS (MECHANICAL OPERATION), COILS (SPARK), ENGINE MECHANICS - END Note A: SEE THE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/AIR TEMPERATURE SENSOR" CHAPTER. Note B: SEE THE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/ENGINE TEMPERATURE SENSOR" CHAPTER. Note C: SEE THE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/LAMBDA PROBE" CHAPTER. Note D: SEE THE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/THROTTLE BODY" CHAPTER.
See also
Checks and inspections
TROUBL - 3
Troubleshooting
SL 750 SHIVER
AXONE SHOULD BE WORKING PROPERLY AND UPGRADED TO THE 5.1.5 VERSION MINIMUM.
CAUTION
BEFORE ANY TROUBLESHOOTING, MAKE SURE THAT: 1) BATTERY VOLTAGE IS ABOVE 12V; 2) THE MAIN 30A FUSE IS NOT DAMAGED AND IS ADEQUATELY FITTED; 3) AUXILIARY FUSES ARE NOT DAMAGED AND ARE ADEQUATELY FITTED.
NOTE
THE RELAY NUMBER SPECIFIED REFERS TO THE WIRING DIAGRAM. THE POSITION OF THE RELAY ON THE VEHICLE IS INDICATED IN THE "ELECTRICAL SYSTEM/COMPONENT LAYOUT/ RELAY LAYOUT" CHAPTER. 1 - WITH THE KEY TURNED TO "ON", THE INSTRUMENT PANEL LIGHTS UP BUT NO FAILURE INDICATION IS SHOWN. IS THE FUEL PUMP ACTIVATED? YES, go to 27; NO, go to 2 2 - DOES AXONE COMMUNICATE WITH THE CONTROL UNIT? YES, go to 3; NO, go to 4 3 - ACTIVATE ONE INJECTOR BY MEANS OF AXONE ("DEVICES ACTIVATION" SCREEN PAGE, INJECTOR ICON): IS THE INJECTOR ACTIVATED? YES, go to 17; NO, go to 12 4 -WITH THE KEY TURNED TO "OFF" CHECK IF THERE IS VOLTAGE ON THE ORANGE/ RED CABLE OF THE MAIN INJECTION RELAY (POLARISED) 41. YES, go to 6; NO, go to 5 5 - INSPECT IF THERE IS AN INTERRUPTION IN THE ORANGE/RED CABLE FROM THE MAIN INJECTOR RELAY (POLARISED) TO THE BATTERY POSITIVE. 6 - WITH THE KEY TURNED TO "ON" CHECK IF THERE IS VOLTAGE ON THE GREEN/ BLACK CABLE OF THE MAIN INJECTION RELAY (POLARISED) 41. OK, go to 8; NOT OK, go to 7 7 - INSPECT THE GREEN/BLACK CABLE FROM THE MAIN INJECTION RELAY (POLARISED) 41 TO THE KEY SWITCH - END 8 - IS THE BLUE CABLE GROUNDED? YES, go to 10; NO, go to 9 9 - RESTORE THE CABLE HARNESS. 10 - CHECK IF THERE IS VOLTAGE ON THE RED/BLACK CABLE. NOT OK, go to 11; OK, go to 12 TROUBL - 4
SL 750 SHIVER
Troubleshooting
11 - REPLACE THE MAIN INJECTOR RELAY (POLARISED) 41 - END 12 - CHECK IF THERE IS VOLTAGE ON THE ORANGE/RED CABLE OF THE AUXILIARY INJECTION RELAY (POLARISED) 42. YES, go to 13; OK, go to 14
13 - CHECK IF THERE IS VOLTAGE ON THE YELLOW/PURPLE CABLE. OK, go to 15; NOT OK, go to 16
14 - RESTORE THE CABLE HARNESS - END 15 - SET THE KEY TO "OFF" AND THEN "ON": DOES THE VOLTAGE ON THE YELLOW/ PURPLE CABLE REACH APPROX. 1-2V FOR 2 SECONDS? YES, go to 17; NO, go to 18
16 - REPLACE THE AUXILIARY INJECTOR RELAY (POLARISED) 42 - END 17 - WHEN THE KEY IS TURNED TO "OFF", CHECK CONTINUITY AND GROUND INSULATION OF THE RED/BROWN CABLE FROM THE AUXILIARY INJECTION RELAY 42 TO THE FUEL PUMP CONNECTOR. YES, go to 20; NO, go to 19
18 - WHEN THE KEY IS TURNED TO "OFF", CHECK CONTINUITY AND GROUND INSULATION OF THE YELLOW/PURPLE CABLE FROM THE RELAY TO PIN 62, VEHICLE CONNECTOR. YES, go to 22; NO, go to 21
19 - RESTORE THE CABLE HARNESS. 20 - CHECK THERE IS GROUND INSULATION FOR THE BLUE CABLE OF THE PUMP CONNECTOR. OK, go to 24; NOT OK, go to 23
21 - RESTORE THE CABLE HARNESS - END 22 - CHECK THE VEHICLE CONNECTOR. OK, go to 25; NOT OK, go to 26
23 - RESTORE THE CABLE HARNESS - END 24 - CHECK IF THE PUMP RESISTANCE IS APPROX. 1 OHM. REPLACE THE PUMP IF THE RESISTANCE VALUE IS NOT THAT SPECIFIED - END 25 - REPLACE THE CONTROL UNIT - END 26 - RESTORE THE CABLE HARNESS - END 27 - DOES THE MOTOR TURN WHEN THE STARTER BUTTON IS PRESSED? YES, go to 29; NO, go to 28
28 - WHAT DOES THE "START-UP ENABLING SWITCH" STATUS ON AXONE (DEVICE STATUS/ICON "0/1" SCREEN PAGE) MEAN? YES, go to 43; NO, go to 64 TROUBL - 5
Troubleshooting
SL 750 SHIVER
29 - VOLTAGE TO THE YELLOW/PINK CABLE OF THE RETENTION RELAY (START-UP LOGIC) 39 OK, go to 30; NOT OK, go to 31
30 - WITH THE RETENTION RELAY (START-UP LOGIC) 39 DISCONNECTED, KEEP THE STARTER BUTTON PRESSED AND CHECK IF THERE IS APPROX. 1-2V VOLTAGE IN THE YELLOW/RED CABLE OK, go to 32; NOT OK, go to 33
31 - RESTORE THE CABLE HARNESS 32 - CHECK THE GROUND CONNECTION OF THE BLUE CABLE OF THE RETENTION RELAY (START-UP LOGIC) 39
OK, go to 34; NOT OK, go to 35 33 - RESTORE THE CABLE HARNESS 34 - CHECK THAT THE RETENTION RELAY (START-UP LOGIC) 39 WORKS CORRECTLY OK, go to 36; NOT OK, go to 37 35 - RESTORE THE CABLE HARNESS 36 - CHECK CONTINUITY OF THE PINK/BLACK CABLE OF THE RETENTION RELAY (START-UP LOGIC) 39 TO PIN 14 VEHICLE CONNECTOR OK, go to 38; NOT OK, go to 39 37 - REPLACE THE RETENTION RELAY (START-UP LOGIC) 39 38 - CHECK THE VEHICLE CONNECTOR (PIN 14) OK, go to 40; NOT OK, go to 41 39 - RESTORE THE CABLE HARNESS 40 - REFER TO THE CHAPTER ON "ELECTRICAL SYSTEM/ CHECKS AND CONTROLS/ ENGINE REVOLUTION SENSOR"; FOLLOW THE TROUBLESHOOTING STEPS IN THE SECTION REFERRING TO "AXONE: ELECTRICAL ERRORS". CAUTION: failure NOT identified, go to 42; failure identified, END 41 - RESTORE THE CABLE HARNESS 42 - CHECK INJECTORS AND ENGINE FOR CORRECT MECHANICAL OPERATION, CHECK FUEL CIRCUIT PRESSURE. 43 - WHEN THE STARTER BUTTON IS PRESSED, DOES THE VOLTAGE TO THE YELLOW/PINK CABLE OF THE CONTROL RELAY (START-UP LOGIC) 40 REACH APPROX. ZERO? YES, go to 44; NO, go to 45
TROUBL - 6
SL 750 SHIVER
Troubleshooting
44 - CHECK IF THERE IS VOLTAGE IN THE RED/BLACK CABLES ON THE CONTROL RELAY (START-UP LOGIC) 40 YES, go to 50; NO, go to 51
45 - CHECK CONTINUITY AND GROUND INSULATION OF THE YELLOW/PINK CABLE FROM THE RELAY TO THE ENGINE CONNECTOR (PIN 2) OK, go to 47; NOT OK, go to 46
46- RESTORE THE CABLE HARNESS - END 47 - CHECK THE CONTROL UNIT CONNECTOR OK, go to 49; NOT OK, go to 48
48 - RESTORE THE CABLE HARNESS - END 49 - REPLACE THE CONTROL UNIT - END 50 - PRESSING THE STARTER BUTTON, DISCONNECT THE CONNECTOR OF THE WHITE/SKY BLUE AND WHITE/RED CABLES OF THE START-UP RELAY 36, AND CHECK IF THERE IS VOLTAGE TO THE YELLOW/RED CABLE OF THE CONTROL RELAY- START-UP LOGIC- 40 OK, go to 52; NOT OK, go to 53
51 - REPLACE THE RELAY - END 52 - PRESSING THE STARTER BUTTON, CHECK IF THERE IS VOLTAGE TO THE YELLOW/RED CABLE OF THE START-UP RELAY OK, go to 54; NOT OK, go to 55
53 - REPLACE THE RELAY - END 54 - CHECK IF THE BLUE CABLE OF THE START-UP RELAY 36 IS GROUNDED OK, go to 56; NOT OK, go to 57
55 - RESTORE THE CABLE HARNESS -END 56 - WITH THE KEY TURNED TO "OFF" CHECK IF THERE IS VOLTAGE TO THE REAR RED CABLE (WITH PROTECTION COVER) OF THE START-UP RELAY 36 OK, go to 58; NOT OK, go to 59
57 - RESTORE THE CABLE HARNESS -END 58 - PRESSING THE STARTER BUTTON, CHECK IF THERE IS VOLTAGE TO THE FRONT RED CABLE OF THE START-UP RELAY 36 OK, go to 60; NOT OK, go to 61
59 - RESTORE THE CABLE HARNESS 60 - CHECK CONTINUITY OF THE RED CABLE BETWEEN THE START-UP RELAY 36 AND THE STARTER MOTOR YES, go to 62; NO, go to 63
TROUBL - 7
Troubleshooting
SL 750 SHIVER
61 - REPLACE THE START-UP RELAY 36 - END 62 - REPLACE THE STARTER MOTOR - END 63 - RESTORE THE CABLE HARNESS - END 64 - WHAT DOES THE "FALL SENSOR" STATUS ON AXONE (DEVICE STATUS/ICON "0/1" SCREEN PAGE) MEAN? If "NORMAL" is shown, go to 65; If "TIP OVER" is shown, go to 68
65 - WITH THE SWITCH SET TO "RUN", WHAT DOES THE "RUN-STOP SWITCH" STATUS ON AXONE ("DEVICE STATUS/ICON "0/1" SCREEN PAGE) MEAN? If "RUN" is shown, go to 66; If "STOP" is shown, go to 67
66 - USING AXONE CHECK THAT THE SIDE STAND, NEUTRAL SENSOR AND CLUTCH SENSOR FUNCTION CORRECTLY; OPERATE ANY DEVICE AND CHECK THE SUITABLE INDICATION ON THE "DEVICE STATUS/ICON "0/1" SCREEN PAGE
If "MALFUNCTION" is shown, go to 71; If "CORRECT OPERATION" is shown, go to 72 67 - REFER TO THE CHAPTER ON "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/ FALL SENSOR; INDICATION ON AXONE ALWAYS STOP- END 68 - IS THE SENSOR VERTICAL? YES, go to 69; NO, go to 70 69 - REFER TO THE CHAPTER ON "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/ FALL SENSOR; INDICATION ON AXONE ALWAYS TIP OVER - END 70 - SET THE SENSOR TO THE CORRECT POSITION - END 71 - ACCORDING TO THE FAILURE, REFER TO CHAPTER ON "ELECTRICAL SYSTEM/ CHECKS AND CONTROLS/GEAR IN NEUTRAL SENSOR", or "CLUTCH LEVER SENSOR" or "SIDE STAND SENSOR" - END 72 - REPLACE THE CONTROL UNIT - END
TROUBL - 8
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
SL 750 SHIVER
Components arrangement
Key 1. Revolution sensor 2. Intake air pressure sensor 3. Intake air temperature sensor
ELE SYS - 2
SL 750 SHIVER
Electrical system
4. Instrument panel 5. Air temperature sensor for instrument panel indication 6. Front headlamp 7. Start-up relay 8. Coils 9. Spark plugs 10.Starter motor 11.Rear light 12.Auxiliary fuses 13.Main fuses 14.Throttle grip position sensor 15.Gear in neutral sensor 16.Revolution sensor - pick up 17.Engine temperature sensor 18.Throttle control unit 19.Lambda probe 20.Fall sensor 21.Main injection relay 22.Engine control unit
CAUTION
A RELAY CANNOT BE IDENTIFIED BASED ONLY ON THE FOLLOWING INDICATIONS: THIS SHOULD BE DONE ALSO IDENTIFYING THE COLOUR OF THE RELAY CABLES. RELAY LAYOUT ON THE WIRING DIAGRAM AND ON THE VEHICLE LIGHT LOGIC RELAY Location on the wiring diagram: 9 Location on the vehicle: under the fuel tank, left side, second relay starting from the front.
START-UP RELAY Location on the wiring diagram: 36 Location on the vehicle: under the fuel tank, right side, fifth relay starting from the front, below in relation to the line of the other relays. RETENTION RELAY Location on the wiring diagram: 39 Location on the vehicle: under the fuel tank, right side, second relay starting from the front.
CONTROL RELAY Location on the wiring diagram: 40 Location on the vehicle: under the fuel tank, right side, first relay starting from the front.
ELE SYS - 3
Electrical system
SL 750 SHIVER
Location on the wiring diagram: 41 Location on the vehicle: under the saddle.
AUXILIARY INJECTION RELAY Location on the wiring diagram: 42 Location on the vehicle: under the fuel tank, right side, third relay starting from the front.
FAN CONTROL RELAY Location on the wiring diagram: 44 Location on the vehicle: under the fuel tank, left side, first relay starting from the front.
HIGH-BEAM LIGHTS RELAY Location on the wiring diagram: 66 Location on the vehicle: under the fuel tank, left side, third relay starting from the front.
RECOVERY LOGIC RELAY (URGENT SERVICE) Location on the wiring diagram: 67 Location on the vehicle: under the fuel tank, right side, fourth relay starting from the front.
Vehicle sections The wiring distribution is subdivided in three essential sections, as indicated in the figure. ELE SYS - 4
SL 750 SHIVER
Electrical system
SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES Carry out the checks described below once the electrical system is refitted, connectors reconnected and clamps and retainers restored. Check the connector block for connections and correct tightening in the following connectors. 1. Instrument panel connector: FRONT SECTION, TABLE J. 2. Handgrip sensor connectors: CENTRAL SECTION, TABLE F. 3. Pick Up Connector: CENTRAL SECTION, TABLE Q. 4. Side Stand Switch Connector. 5. Regulator Connector: CENTRAL SECTION, TABLE H. 6. Front cylinder coil and rear cylinder coil connectors: CENTRAL SECTION, TABLE F. 7. Filter Housing Connectors: CENTRAL SECTION, TABLE F. 8. ECU and Ground Lead Connectors for the filter casing: CENTRAL SECTION, TABLE A. 9. Fuel Pump Connector: CENTRAL SECTION, TABLE F. 10.Key Connector - Right Light Switch Connectors - Left Light Switch Connectors: Connectors inside the housing behind the radiator: FRONT SECTION, TABLE I. THE CONNECTORS LISTED ARE CONSIDERED CRITICAL IN COMPARISON WITH THE OTHERS BECAUSE THE VEHICLE WILL STOP IF THEY ARE ACCIDENTALLY DISCONNECTED. Undoubtedly the connection of the rest of connectors is also important and essential for the correct operation of the vehicle.
Front side
CAUTION
ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELECTRICAL SYSTEM INSTALLATION" SECTION. ELE SYS - 5
Electrical system
SL 750 SHIVER
TABLE A - SWITCHES 1. Right switch cable harness 2. Left switch cable harness Introduce carefully the cap on the cable harnesses (1 and 2) of the switches.
TABLE B - RIGHT SWITCH CABLE HARNESS RETAINER Fasten the right switch cable harnesses with a rubber clamp.
TABLE C - LEFT SWITCH CABLE HARNESS RETAINER Fasten the left switch cable harnesses with a rubber clamp.
ELE SYS - 6
SL 750 SHIVER
Electrical system
TABLE D - CLUTCH CABLE, THROTTLE CABLE With a small clamp, not pulled clamp, fasten the clutch cable to the throttle cable.
TABLE E - INSTRUMENT PANEL CABLES Fasten the instrument panel cable braid to the chassis with a medium clamp.
ELE SYS - 7
Electrical system
SL 750 SHIVER
TABLE F - INSTRUMENT PANEL CABLES 1. The two medium clamps shall be positioned so that they match the corresponding sections of chassis indicated through two turns of red belt. 2. Place the clamp as close as possible to the chassis vertical tube.
TABLE G - AIR TEMPERATURE CONNECTOR AND FRONT HEADLAMP CABLE Use a small clamp to fasten the air temperature connector and the front headlamp cable to the main cable harness.
TABLE H - COIL CABLE Fasten the coil cable with a small clamp.
TABLE I - HOUSING AND CENTRAL CABLE GUIDE 1. The housing containing light switch and key connectors shall be placed freely over the branch with the clamp and not fixed. 2. Place medium clamps on the central cable guide that holds only the branch that leads to the filter casing left side.
ELE SYS - 8
SL 750 SHIVER
Electrical system
TABLE J - INSTRUMENT PANEL 1. Place a small clamp on the left turn indicator connector and the main trunk. 2. The immobilizer aerial connector is fitted between the plate and the instrument panel. 3. Lift the external air temperature sensor upwards once it is connected.
Parte centrale
CAUTION
ELE SYS - 9
Electrical system
SL 750 SHIVER
ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELECTRICAL SYSTEM INSTALLATION" SECTION. TABLE A - CONTROL UNIT, MAIN CABLE HARNESS, HORN AND NEUTRAL SENSOR CABLES 1. ECU 2. Engine Connector 3. Vehicle Connector 4. ECU ground connection 5. Horn and neutral sensor cables 6. Main cable harness The horn and neutral sensor cables shall be laid over the water pipe upon installation.
TABLE B - UNDER SEAT CABLE HARNESS 1. Use small clamps to fasten the cables. 2. Use medium clamps to fasten the main cable harness.
ELE SYS - 10
SL 750 SHIVER
Electrical system
TABLE C - MAIN CABLE HARNESS The main cable harness is laid between the relay and the fall sensor, under the fall sensor connector.
TABLE D - DIAGNOSIS CONNECTORS Fasten both diagnosis connectors with a small clamp, under the cable harness main branch.
TABLE E - CABLE HARNESSES UNDER THE TANK 1. Fasten the pipe with two medium clamps. 2. The flywheel and side stand cables shall be laid through the cable guide screwed to the filter housing. 3. Bunch the cables with clamps. 4. Fasten with a clamp cables on the filter housing and the rear cylinder coil.
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TABLE F - CABLE HARNESSES UNDER THE TANK 1. Place clamps at the connector sides. 2. Mark the connection on the left side using the BLUE belt. 3. Mark the connection on the right side using the WHITE belt. 4. Fasten with a medium clamp.
TABLE G - HANDGRIP SENSOR CONNECTOR 1. Fitting the connector in the handgrip sensor. 2. Closing the connector block. 3. During step (1), move the hook (3) forwards.
TABLE H - LEFT SIDE CABLE HARNESS UNDER THE TANK Identify the regulator output with the WHITE belt.
1. Fasten the cable harness with a clamp. 2. Connector for resistance module. ELE SYS - 12
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3. Fasten the cables with a clamp and hold also the control unit upper branch.
TABLE I - PICK-UP AND ENGINE CONTROL UNIT CABLE HARNESSES 1. Cable harness path towards the engine control unit connectors. 2. Pick-up cable harness path.
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1. Use a small clamp to keep the cable fixed to the oil bulb cap. 2. Use a small clamp behind the pipe so that the oil and start-up cable is tightened to the rear pipe. 3. Fasten the cable with medium clamps.
TABLE K - NEUTRAL SENSOR CABLE HARNESS Place the neutral sensor cable harness as shown and fasten it with a small clamp where indicated.
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TABLE L - LAMBDA PROBE Place two clamps to fasten the cable harness to the chassis, as indicated: 1. medium clamp; 2. small clamp.
TABLE M1 - FILTER CASING CABLE HARNESS Place both throttle valve position sensors.
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TABLE M4 - FILTER HOUSING Insert the throttle body, with the cable harness correctly fixed, in the filter casing.
TABLE N - GROUND LEAD AND START-UP CABLE Fit the ground lead following the path drawn in figure that will not be visible on the vehicle once fully assembled. As indicated above, the ground lead is laid behind the filter casing pipe. As regards the lower section, the cable is laid behind the starter motor plate. In the central position, insert a small clamp joining the ground lead and the oil cable to the smallest pipe.
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TABLE O - GROUND LEAD AND START-UP CABLE 1. Direct the cable as shown in figure. 2. Before fitting the cable, push the sheath to the panel terminal so as to hide the RED cable (see box). 3. Fasten the cable with a clamp 10-mm (0.39 in) long. TABLE P - GROUND LEAD AND START-UP CABLE 1. Fasten the cable with clamps where indicated. 2. Be careful not to hold the MAP sensor pipe with the clamp. 3. Place the cable harness as shown.
Back side
CAUTION
ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELECTRICAL SYSTEM INSTALLATION" SECTION. TABLE A - REAR LIGHT CABLE HARNESS 1. Rear right turn indicator: BLACK and RED cables. 2. Left turn indicator: BLACK and SKY BLUE cables. 3. Fasten the rear light cable harness to the rear frame with two small clamps. 4. When fitting the cable harness, make sure that the cable harness sheathing is visible in the indicated area of the curved support.
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Key: 1. MULTIPLE CONNECTORS 2. RIGHT FRONT TURN INDICATOR 3. COMPLETE FRONT HEADLAMP 4. TAIL LIGHT BULB
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5. LOW-BEAM BULB 6. HIGH-BEAM BULB 7. FRONT LEFT TURN INDICATOR 8. AMBIENT AIR TEMPERATURE SENSOR 9. SWITCH LIGHTS LOGIC RELAY 10.CLUTCH 11.HORN 12.LEFT LIGHT SWITCH 13.INSTRUMENT PANEL 14.RIGHT LIGHT SWITCH 15.OIL PRESSURE SENSOR 16.INSTRUMENT PANEL DIAGNOSIS 17.SIDE STAND SWITCH 18.ECU DIAGNOSIS 19.IMMOBILIZER AERIAL 20.KEY SWITCH 21.REAR LEFT TURN INDICATOR 22.REAR RIGHT TURN INDICATOR 23.LICENSE PLATE LIGHT BULB 24.REAR TWIN LIGHT / STOP LIGHT BULB 25.REAR LIGHT ASSEMBLY 26.REAR STOP SWITCH 27.FRONT STOP SWITCH 28.SPEED SENSOR 29.FALL SENSOR 30.NEUTRAL SENSOR 31.TIMING SENSOR (OPTIONAL) 32.AUXILIARY FUSES 33.FLYWHEEL 34.VOLTAGE REGULATOR 35.STARTER MOTOR 36.START-UP RELAY 37.MAIN FUSE 38.BATTERY 39.RETENTION RELAY (START-UP LOGIC) 40.CONTROL RELAY (START-UP LOGIC) 41.MAIN INJECTION RELAY (POLARISED) 42.AUXILIARY INJECTION RELAY (POLARISED) ELE SYS - 20
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43.FAN 44.FAN CONTROL RELAY 45.FUEL LEVEL SENSOR 46.FUEL PUMP 47.REAR CYLINDER COIL 48.FRONT CYLINDER COIL 49.REAR CYLINDER SPARK PLUG 50.FRONT CYLINDER SPARK PLUG 51.INTAKE AIR TEMPERATURE SENSOR 52.ENGINE TEMPERATURE SENSOR 53.LAMBDA PROBE 54.PURGE VALVE (OPTIONAL) 55.REAR CYLINDER PRESSURE SENSOR 56.FRONT CYLINDER PRESSURE SENSOR 57.REAR CYLINDER INJECTOR 58.FRONT CYLINDER INJECTOR 59.EFG 1X THROTTLE CONTROL UNIT (MARELLI) 60.REAR CYLINDER THROTTLE 61.FRONT CYLINDER THROTTLE 62.THROTTLE GRIP POSITION SENSOR 63.PICK-UP 64.ECU 65.HAZARD BUTTON LIGHTING 66.HIGH-BEAM LIGHT RELAY 67.RECOVERY LOGIC RELAY Colour key: Ar Orange Az Sky blue B Blue Bi White G Yellow Gr Grey M Brown N Black R Red Ro Pink V Green
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Vi Purple
BEFORE CARRYING OUT ANY TROUBLESHOOTING PROCEDURE ON THE VEHICLE, CHECK THAT THE BATTERY VOLTAGE IS ABOVE 12V. CONNECTOR CHECK PROCEDURE The procedure includes the following checks: 1. Observation and check of the connector position on the component or on the coupling connector, making sure that the locking catch is released. 2. Observation of the terminals on the connector: no rust marks or dirt should be present and it is important to check terminal correct positioning on the connector (i.e., all terminals aligned at the same depth) and terminal integrity (i.e., that terminals are not loose, open/bent, etc.). For connectors whose terminals are not visible (e.g. Marelli control unit) use a metal cable of suitable diameter and introduce it carefully in the connector slot at the same depth as for the other terminals of the connector.
CAUTION
IN CASE OF TEMPORAL MALFUNCTIONING, CARRY OUT ALL DUE CHECKS LOOKING FOR FAILURES BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED. 3. Pulling the cables slightly from the back of the connector in order to check the correct position of the terminals on the connector and of the cable on the terminal. CONTINUITY check Check goal: this control is to check that there are not any circuit interruptions nor excessive resistance, for instance caused by rust, on the two terminals being inspected. ELE SYS - 22
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Tester: set the tester on the "continuity" symbol and place the tester probes on the two circuit ends: the tester emits a sound signal only if there is continuity; the tester can also be set to the Ohm symbol to check that the circuit resistance is null or a few tenths of an Ohm. CAUTION: THE CIRCUIT SHOULD NOT BE ENERGISED, OTHERWISE THE TEST IS IRRELEVANT. GROUND CONNECTION check Check goal: this control is to check if a cable or a circuit is in contact with the vehicle ground (-) connection. Tester: set the tester on the "continuity" symbol and place one tester probe on the vehicle ground connection (or on the battery - terminal) and the other probe on the cable being inspected: the tester sends out a sound signal only if there is continuity. The tester can also be set to the Ohm symbol to check that the circuit resistance is null or a few tenths of an Ohm. CAUTION! IF THERE IS A GROUND CONNECTION COMING FROM THE CONTROL UNIT, MAKE SURE THAT DURING THE TEST THE CONTROL UNIT IS EARTH CONNECTED TO THE CIRCUIT. VOLTAGE check Check goal: this control is to check if a cable is energised, i.e. if it receives power supply from the battery or the control unit. Tester: set the tester on the direct current symbol and place the tester red probe on the cable being inspected and the black probe on the vehicle ground connection (or on the battery - terminal).
CAUTION
IN CASE OF TEMPORAL MALFUNCTIONING, CARRY OUT ALL DUE CHECKS LOOKING FOR FAILURES BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED.
Dashboard
In case the EFI warning light turns on and the words SERVICE or URGENT SERVICE are shown on the display, due to an error detected in the injection ECU, the malfunction indication will be deactivated only after the vehicle has been used for a pre-set number of minutes of operation. However, even though the malfunction is no longer present and the control unit considers the error no longer current but memorised (MEM error indication on Axone), the instrument panel may keep showing there is an error present.
Diagnosis
An access code is required to enter this menu which controls the diagnosis function: ENTER SERVICE CODE
This is a 5-digit code, fixed for each vehicle. For these vehicles, the code is: 12398 If the code is incorrect, the following message is displayed:
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INCORRECT CODE
and the instrument panel goes back to the main menu. Otherwise, the following menu is displayed: EXIT ECU DIAGNOSIS INSTRUMENT PANEL ERRORS ERROR CLEARING VEHICLE SERVICING RESET UPDATE CHANGE KEYS KM / MILES
ECU DIAGNOSIS In this mode a chart is displayed showing potential errors in the control unit. IT IS NECESSARY REFER TO THE ERROR INDICATIONS GIVEN BY AXONE FOR THIS VEHICLE.
The instrument panel does not keep all previous errors stored in its memory. INSTRUMENT PANEL ERRORS In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connected to it.
Instrument panel errors In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connected to it. DSB 01 - Immobilizer failure: key code read but not recognised. DSB 02 - Immobilizer failure: key code not read (key not present or transponder not working) DSB 03 - Immobilizer failure: aerial not working (open or short-circuited) DSB 04 - Internal controller failure DSB 05 - DSB 06 - Ambient air temperature sensor Error cause ELE SYS - 24
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An oil sensor failure is signalled when it is detected that the sensor circuit is open or shorted to positive.
DSB 07 - Oil pressure sensor Error cause An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit is open. Troubleshooting The test is performed only once when the key is set to ON. This error is signalled by the bulb icon, and the general warning light turns on as well. DSB 08 - Oil pressure sensor Error cause An oil sensor failure is signalled when, with engine running, it is detected that the sensor circuit is closed. There is an error when the general warning light turns on. Troubleshooting This error is signalled by the bulb icon, and the general warning light turns on as well. The instrument panel must keep all previous errors stored in its memory. ERROR CLEARING This option deletes all instrument panel errors; a further confirmation is requested. Use Axone to reset ECU errors. VEHICLE SERVICING RESET This function is used to reset vehicle servicing. Using this function, the odometer can be reset only once within the first 200 km (124 mi) of the vehicle, provided this has not been done by the Quality Check. UPDATE This function is used to program the instrument panel again. This screen page shows the software version currently loaded; the LCD reads: INSTRUMENT PANEL DISCONNECTED. NOW CONNECT THE DIAGNOSIS INSTRUMENT. The instrument panel will restart to work normally after the key is inserted-extracted. CHANGE KEYS With this function the instrument panel can update the keys. Up to 4 keys can be stored. The user code is first requested to be entered: ENTER THE CODE
After entering the correct code, the following message should be shown on the display: INSERT THE X KEY INSERT THE X+1 KEY
At least one key must be programmed for the next start-ups. If no other key is inserted within 20 seconds or if there is no power or after the fourth key is programmed, the procedure finishes and all the functions of the vehicle and the instrument panel must be enabled (even if only one key has been programmed). ELE SYS - 25
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KM / MILES This menu selects the unit of measurement, either for the speed or the total or partial odometers. KM MILES
LANGUAGES Select the user interface language from this menu. ITALIANO ENGLISH FRANCAIS DEUTSCH ESPAGNOL
See also
Diagnosis
level indicators
Fuel reserve sensor Check proper operation of the sensor by adding a 2W bulb in series to the sensor. Place a bulb between the battery power supply cable and the connector terminal and connect the negative terminal to the ground connection: if the sensor is submerged in petrol (sensor high electrical resistance, approx. 5-7 kOhm), the bulb should remain off. if the sensor is not submerged in petrol, the bulb should turn on.
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Lights list
Front headlamp
Characteristic
Front tail light 12V - 5W x 2 Low-beam light 12 V - 55 W H7 High-beam light 12 V - 55 W H7 Rear light
Characteristic
Rear tail light / stop light 12V - 5/21W x 2
Fuses
AUXILIARY FUSES A - Coil, Light logic relay, Recovery logic relay, Stop, Horn, Tail lights, License plate light (10A). B - Low-beam / high-beam lights (15A). C - Live positive lead to EFG-1x control unit and to instrument panel, Instrument panel diagnosis (10 A). D - Instrument panel, Ride by wire (15 A). E - Permanent positive, ECU power supply (3A). F - Lambda heater, coils, Start-up logic, Fan and injection relay, Fuel pump, Purge valve, Injectors, ECU, Start-up logic (20 A). G - Spare fuses (10 - 15 - 20 A) MAIN FUSES H - Spare fuses (30 A) I - Battery recharge, vehicle loads and injection loads (30 A)
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Control unit
MARELLI CONTROL UNIT Function It controls the Ride by wire system, the injection/ ignition, the system safety checks and the self-diagnosis function. Location: left side, next to the engine
Connector location: ENGINE connector: upper connector with control unit on the vehicle; a letter E is stamped on the control unit, to the right of the connector. VEHICLE connector: lower connector with control unit on the vehicle; a letter V is stamped on the control unit, to the right of the connector. Pin-out: see the CONNECTORS section AXONE: STATUSES Engine status Example value:Indefinite_Key ON_Running engine_Stopped_Power latch_Power latch 2_Power latch finished Engine mode Example value: Indefinite_Start-up_Stable_Idle_Acceleration_Deceleration_Enters Cut Off_Cut Off_Exits Cut Off Immobilizer signal Example value: yes/no Indicates whether the control unit has received the consent by the instrument panel regarding the immobilizer: coded key or user code entered manually. Potential errors will be shown on the Instrument Panel Errors screen page, on the DIAGNOSIS section of the instrument panel. Start-up signal Example value: yes/no Indicates whether the control unit will enable start-up when requested: in case the safety measures are not respected (side stand, neutral sensor and clutch in correct position) or if the immobilizer does not send the start-up consent to the control unit, the status is NO. AXONE: FUEL INJECTION SYSTEM ELE SYS - 28
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PARAMETERS Target idle rpm AXONE: ELECTRICAL ERRORS EEPROM Error P0601 - circuit not operational. Error cause Replace injection ECU. The instrument panel does not indicate the presence of this error even in the ATT status. RAM Error P0604- circuit not operational. Error cause Replace injection ECU. The instrument panel does not indicate the presence of this error even in the ATT status. ROM Error P0605- circuit not operational. Error cause Replace injection ECU. The instrument panel does not indicate the presence of this error even in the ATT status. A/D converter P0607- circuit not operational. Error cause Replace injection ECU.
Level 2 safety reset P0608 Error cause As the level 2 safety system (comparison between requested torque and calculated torque) has detected a fault, the control unit has reset engine (C gravity). Troubleshooting Continue failure search for the other errors detected .
Safety Engine Stop P0609 Error cause As the level 3 safety system (control EEPROM) has detected a fault, the control unit has shut off the engine (D gravity). Troubleshooting Replace Marelli control unit.
Reset lines error P0610- circuit not operational Error cause Problems on the reset lines (PINS 55 and 56 of the VEHICLE connector) of the throttle motors: lines used to interrupt motor functioning for safety reasons. Troubleshooting ELE SYS - 29
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Check the VEHICLE connector of the Marelli control unit, the filter housing large connector and the throttle control unit connector: if not OK, restore. If OK, check continuity between the Marelli control unit and the throttle control unit connector from VEHICLE PIN 55 to PIN B7 and from PIN 56 to PIN A7: if not OK, restore. If OK, check that with throttle control unit connector disconnected and with key set to ON, there is no voltage on PINS A7 and B7: if there is voltage, replace the cable harness. If there is no voltage, check that PINS A7 and B7 are insulated from ground connection: if they are not insulated from the ground connection, replace the cable harness. If they are insulated, replace the throttle control unit or the Marelli control unit.
AXONE: NOTES After installing the control unit and setting the key to ON, wait for 3 seconds, time during which the control unit detects the throttle valve position. Connect to Axone and check that the status for Throttle Self-learning is Carried out and the status for Throttle grip autodetection is Not carried out(this last status entails Urgent service being displayed on the instrument panel). If Throttle Self-learning shows Not carried out , go to stage 1. If it shows Carried out, go to stage 2. Stage 1: current errors have probably been detected by the control unit: solve these malfunctions and check the Throttle Self-learning status again. Throttle Self-learning can also be checked from the Parameter adjustment (screwdriver and hammer) screen page. Stage 2: Carry out the Throttle Self-learning from the Parameter adjustment (screwdriver and hammer) screen page and check that Throttle Self-learning status is Carried out. If it is not correct or the voltage detected on the throttle is out of scale (check with Axone) or if current errors are probably detected by the control unit: solve these malfunctions and repeat the procedure.
Battery
Characteristic
Battery 12V - 10 Ah
Battery installation
NOTE
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THE FIRST TIME THE ENGINE IS STARTED AFTER RECONNECTING THE BATTERY LEADS, WAIT 20 SECONDS BETWEEN THE MOMENT THE KEY IS SET TO "KEY ON" AND THE MOMENT THE STARTER BUTTON CAN BE PUSHED. THE ENGINE WILL NOT START IF START-UP IS ATTEMPTED BEFORE THE PRE-SET 20 SECONDS.
Speed sensor
VEHICLE SPEED SENSOR Function To indicate the vehicle speed by reading the secondary transmission shaft rotation. Operation / Operating principle Hall-effect sensor: a square-wave pulse is generated with voltage between 0 and approximately 0.3-0.4V. Level in wiring diagram: Speed sensor Location: Pin-out: 1. Ground connection 2. Output signal 3. Supply voltage 5V
CAUTION
on the vehicle: right side, near the clutch cover. connector: on the sensor.
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: PARAMETERS Speed sensor Vehicle speed: km/h AXONE: LOGIC ERRORS Sensor/vehicle speed signal P0500 - over maximum limit/ signal not valid. Error cause If over the maximum limit: excessive signal frequency has been detected at PIN 49 VEHICLE. If signal is not valid: a fault in the signal (no signal, short circuit to positive, open or earthed circuit, defective sensor, open circuit, defective measuring cam, etc.) has been de-
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tected at VEHICLE PIN 49. This requires a longer recognition time that is counted from zero each time the clutch is operated, the gear is set to neutral or the engine is shut off. Troubleshooting if over the maximum limit: replace the sensor. Signal not valid: check the speed sensor connector and the Marelli control unit connector: if not OK, restore. If OK, check that, with key set to ON and the sensor connector disconnected, there is continuity on PIN 1 with the ground connection. If there is no continuity, set the key to OFF and check that there is continuity between ENGINE PIN 36 and PIN 1 of the sensor connector. If there is not, replace the control unit; if there is, check that there is voltage at PIN 3 coming from the control unit (approximately 5V): if there is no voltage, set the key to OFF and check that there is continuity between the ENGINE PIN 13 and PIN 3. If there is continuity, replace the control unit; if there is not, restore the cable harness; if there is 5V voltage, set the key to OFF and check that there is continuity between the VEHICLE PIN 49 and the sensor PIN 2: if there is no continuity, restore the cable harness. If there is continuity, check that the cam that reads the signal is in good conditions: if it is not, replace it. If it is OK, replace the sensor . SENSOR REMOVAL Remove the rear shock absorber. Undo and remove the screw.
NOTE
IT IS STRICTLY FORBIDDEN TO USE THE VEHICLE WITH THE SPEED SENSOR DISCONNECTED. BESIDES VEHICLE SPEED, THIS SENSOR COMMUNICATES OTHER OPERATION PARAMETERS TO THE CONTROL UNIT.
See also
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Removing
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: PARAMETERS Engine rpm AXONE: STATUSES Synchronised panel Example value:Start-up_Lean_Rich_Fault due to rich value_Fault due to lean value If the probe connector is removed (voltage almost equal to zero), the status is Fault due to lean value Example value:No_under analysis_standby_Yes The parameter refers to the engine revs signal: in case the signal has not been correctly identified yet, the under analysis or standby statuses may be displayed. AXONE: ACTIVATIONS ELE SYS - 33
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IF THE ELECTRIC CIRCUIT IS INTERRUPTED OR SHORT-CIRCUITED OR NO ERROR IS DISPLAYED, CHECK THE REVOLUTION SENSOR CONNECTOR AND THE MARELLI CONTROL UNIT CONNECTOR: IF NOT OK, RESTORE; IF OK, CHECK THE SENSOR ELECTRIC CHARACTERISTIC IS THE CORRECT ONE: IF IT IS NOT, REPLACE THE SENSOR. IF IT IS THE CORRECT ONE, CHECK THAT THERE IS CONTINUITY ON BOTH CABLES, SUPPLY INSULATION AND GROUND CONNECTION INSULATION. CARRY OUT THE TESTS FROM THE SENSOR CONNECTOR TO THE SENSOR. IF NOT OK, RESTORE THE CABLE HARNESS/REPLACE THE SENSOR. IF OK, PERFORM THE TEST FROM PINS 9 AND 23 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR. AXONE: LOGIC ERRORS Engine revolution sensor P0336 - Synchronism lost Error cause Displayed if the signal is not as the control unit expects, for example due to voltage fluctuations not correctly repeated. Troubleshooting Check that the flywheel teeth are clean and the sensor is adequately placed in its fitting: if not OK, restore; if OK, replace the sensor.
Electrical characteristics: Not detected by a multimeter as they are contactless: read voltage on the 4 tracks through Axone.
CAUTION
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BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
CAUTION
THE TWO CONNECTORS WHICH GET TO THE THROTTLE GRIP SENSOR ARE ALIKE BUT THEY SHOULD NEVER BE INVERTED. MARK OR CHECK THE CONNECTOR MARKING BEFORE REMOVING THEM (BLUE STAMP + BLUE BAND). THE CONNECTOR AND THE BLUE BAND SHOULD BE PLACED TO THE LEFT. THE CONNECTOR AND THE WHITE BAND SHOULD BE PLACED TO THE RIGHT.
AXONE: PARAMETERS Left side throttle grip position sensor - track A Example value: 1107 mV Voltage value of the left potentiometer track A Left side throttle grip position sensor - track B Example value: 1107 mV Voltage value times 2 of the left potentiometer track B Right side throttle grip position sensor - track C 3560 mV Voltage value of the left potentiometer track C Right side throttle grip position sensor - track D 3555 mV Voltage value times 2 of the left potentiometer track D Throttle grip position sensor 1107 mV Voltage corresponding to the potentiometer track A Throttle grip opening percentage 0%
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With a released throttle grip, the value read should be 0%, whereas 100 % should be read with throttle grip fully twisted. AXONE: STATUSES Throttle grip Example value:Slightly twisted_choked_fully twisted Throttle grip autodetection Example value: carried out/not carried out AXONE: PARAMETER ADJUSTMENT Throttle grip autodetection AXONE: ELECTRICAL ERRORS Left side throttle grip position sensor track A P0150- short circuit to positive / open circuit, short circuit to negative Error cause If shorted to positive: excessive voltage has been detected at PIN 42 of the VEHICLE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 42 of the VEHICLE connector. Troubleshooting if shorted to positive: check the value shown by the parameter of the left Throttle Grip Position Sensor - track A: disconnect the left connector and see the value displayed by Axone: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero. if the circuit is open, short circuit to negative: check the throttle grip sensor connector and the Marelli control unit connector. If not OK, restore. If OK, check circuit continuity between the two cable terminals. If not OK, restore; if OK, check the cable earth insulation (from the throttle grip sensor connector or the control unit connector): if the cable is not earth insulated, restore the wiring. If it is earth insulated, and with the key set to ON, check that there is power supply for the potentiometer PIN A and that PIN C is connected to earth. If both are correct, replace the throttle grip sensor; if not, check the continuity of the cable that is not functioning properly: if there is continuity, replace the control unit; if not, restore the wiring Left side Throttle Grip Position sensor - track B P0151- short circuit to positive / open circuit, short circuit to negative Error cause Voltage that is excessive / equal to zero has been detected at PIN 40 of the VEHICLE connector. Troubleshooting short circuit to positive: check the value shown by the parameter of the left Throttle Grip position Sensor track B: disconnect the left connector and see the value displayed by Axone: ELE SYS - 36
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if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero. if the circuit is open, short circuit to negative: check the throttle grip sensor connector and the Marelli control unit connector. If not OK, restore. If OK, check circuit continuity between the two cable terminals. If not OK, restore; if OK, check the cable earth insulation (from the throttle grip sensor connector or the control unit connector): if the cable is not earth insulated, restore the wiring. If it is earth insulated, and with the switch key set to ON, check that there is power supply for the potentiometer PIN D and that PIN F is connected to earth. If both are correct, replace the throttle grip sensor; if not, check the continuity of the cable that is not functioning properly: if there is continuity, replace the control unit; if not, restore the wiring. Right side Throttle Grip Position sensor - track C P0152- short circuit to positive / open circuit, short circuit to negative. Error cause If shorted to positive: excessive voltage has been detected at PIN 30 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 30 of the ENGINE connector. Troubleshooting if shorted to positive: check the value shown by the parameter of the right Throttle Grip position Sensor - track C: disconnect the right side connector and see the value displayed by the Axone: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero. if the circuit is open, short circuit to negative: check the throttle grip sensor connector and the Marelli control unit connector. If not OK, restore. If OK, check circuit continuity between the two cable terminals. If not OK, restore; if OK, check the cable earth insulation (from the throttle grip sensor connector or the control unit connector): if the cable is not earth insulated, restore the wiring. If it is earth insulated, and with the key set to ON, check that there is power supply for the potentiometer PIN A and that PIN C is connected to earth. If both are correct, replace the throttle grip sensor; if not, check the continuity of the cable that is not functioning properly: if there is continuity, replace the control unit; if not, restore the wiring Right side Throttle Grip Position sensor - track D P0153 - short circuit to positive / open circuit, short circuit to negative. Error cause If shorted to positive: excessive voltage has been detected at PIN 44 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 44 of the ENGINE connector. Troubleshooting
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if shorted to positive: check the value shown by the parameter of the right Throttle Grip Position Sensor - track D: disconnect the right side connector and see the value displayed by the Axone: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero.
if the circuit is open, short circuit to negative: check the throttle grip sensor connector and the Marelli control unit connector. If not OK, restore. If OK, check circuit continuity between the two cable terminals. If not OK, restore; if OK, check the cable earth insulation (from the throttle grip sensor connector or the control unit connector): if the cable is not earth insulated, restore the wiring. If it is earth insulated, and with the switch key set to ON, check that there is power supply for the potentiometer PIN D and that PIN F is connected to earth. If both are correct, replace the throttle grip sensor; if not, check the continuity of the cable that is not functioning properly: if there is continuity, replace the control unit; if not, restore the wiring.
AXONE: LOGIC ERRORS Left side Throttle Grip Position (tracks A-B) P0154 - illogical signals. Error cause Two illogical voltage signals have been detected at PINS 42 and 40 of the VEHICLE connector (tracks A-B) Troubleshooting Check the parameters of the left Throttle Grip Position Sensor - tracks A and B: if one of the two values clearly deviates from 600-1400 mV, it means that this potentiometer is defective. Check the throttle grip sensor connector and the control unit connector: if not OK, restore. If OK, check that cable resistance between the throttle grip sensor connector and the control unit is a few tenths of Ohm: if this is not the case, restore wiring. If the value is correct, replace the complete throttle grip sensor. Right side Throttle Grip Position (tracks C-D) P0155 - illogical signal. Error cause Two illogical voltage signals have been detected at PINS 30 and 44 of the ENGINE connector (tracks A-B) Troubleshooting Check the parameters of the left Throttle Grip Position Sensor - tracks C and D: if one of the two values clearly deviates from 600-1400 mV, it means that this potentiometer is defective. Check the throttle grip sensor connector and the control unit connector: if not OK, restore. If OK, check that cable resistance between the throttle grip sensor connector and the control unit is a few tenths of Ohm: if this is not the case, restore wiring. If the value is correct, replace the complete throttle grip sensor Throttle Grip position P0156 - illogical signal. Error cause ELE SYS - 38
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The value of the left side sensor (tracks A-B) does not coincide with the value of the right side sensor (tracks C-D).
RESET PROCEDURE If the Marelli control unit or the throttle grip sensor is replaced, check the Throttle grip Autodetection with the diagnosis instrument: once the check is completed, make sure that the throttle grip Autodetection status indicates: carried out.
CAUTION
THE TWO CONNECTORS WHICH GET TO THE THROTTLE GRIP SENSOR ARE ALIKE BUT THEY SHOULD NEVER BE INVERTED. MARK OR CHECK THE CONNECTOR MARKING BEFORE REMOVING THEM (BLUE STAMP + BLUE BAND). THE CONNECTOR AND THE BLUE BAND SHOULD BE PLACED TO THE LEFT. THE CONNECTOR AND THE WHITE BAND SHOULD BE PLACED TO THE RIGHT. NOTES The two connectors which get to the throttle grip sensor are the same but they should NEVER be inverted. Mark or check the connector marking before removing them (blue stamp+blue band). REMOVAL When required, disconnect the corresponding connectors, undo and remove the two screws and remove the throttle grip position sensor.
Electrical system
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AXONE: PARAMETERS Front Cylinder Intake Pressure Example value: 1003 mbar Pressure read by the front sensor. Rear Cylinder Intake Pressure Example value: 1004 mbar Pressure read by the rear sensor. Front Cylinder estimated Intake Pressure Example value: 1003 mbar Pressure estimated by the control unit according to the throttle position. Rear Cylinder estimated Intake Pressure Example value: 1004 mbar Pressure estimated by the control unit according to the throttle position. AXONE: ELECTRICAL ERRORS Front cylinder air pressure sensor P0105 - short circuit to positive / open circuit, short circuit to negative. Error cause If shorted to positive: excessive voltage has been detected at PIN 34 of the VEHICLE connector.
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Electrical system
If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 34 of the VEHICLE connector.
Troubleshooting If short circuit to positive, see that the parameter of the front Cylinder Intake Pressure on the diagnosis instrument reads approx. 1200 mbar; disconnect the large connector from the filter casing: if the value does not vary, it means that the cable is shorted between the filter casing connector and the control unit connector; restore the cable harness. If the value varies, reconnect the filter casing connector and disconnect the sensor connector: if the value does not vary, it means that the cable is shorted between the filter casing connector and the sensor connector; restore the cable harness. Replace the sensor if the value varies. If the circuit is open, short circuit to negative, check filter casing large connector, the Marelli control unit connector and the sensor connector. If not OK, restore. If everything is OK, and with key set to OFF, check if there is continuity between the VEHICLE PIN 34 of the Marelli control unit and the sensor connector PIN 3: if there is no continuity, restore the cable harness. If there is continuity, check the cable earth insulation: if there is continuity to ground, restore the cable harness; if not, with key set to ON check that the voltage on sensor connector PIN 1 is approx. 5 V: if this is not correct, set the key to OFF and check continuity between the ENGINE connector PIN 15 and the sensor connector PIN 1: If not OK, restore the cable harness; if it is OK, replace the control unit. if there is 5V voltage at PIN 1, and with key set to ON, check the continuity to ground of the sensor connector PIN 3: If not OK, restore cable harness; if it is OK, replace the sensor. Rear cylinder air pressure sensor P0106 -short circuit to positive / open circuit, short circuit to negative. Error cause If shorted to positive: excessive voltage has been detected at PIN 5 of the VEHICLE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 5 of the VEHICLE connector. Troubleshooting If short circuit to positive, see that the parameter of the front Cylinder Intake Pressure on the diagnosis instrument reads approx. 1200 mbar; disconnect the large connector from the filter casing: if the value does not vary, it means that the cable is short circuited between the filter casing connector and the control unit connector; restore the cable harness. If the value varies, reconnect the filter casing connector and disconnect the sensor connector: if the value does not vary, it means that the cable is short circuited between the filter casing connector and the sensor connector; restore the cable harness. Replace the sensor if the value varies. ELE SYS - 41
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If the circuit is open, short circuit to negative, check the filter casing large connector, the Marelli control unit connector and the sensor connector; If not OK, restore. If everything is OK, and with key set to OFF, check if there is continuity between the VEHICLE PIN 5 of the Marelli control unit and the sensor connector PIN 3: if there is no continuity, restore the cable harness. If there is continuity, check the cable earth insulation: if there is continuity to ground, restore the cable harness; if not, with key set to ON check that the voltage on sensor connector PIN 1 is approx. 5 V: if this is not correct, set the key to OFF and check continuity between the ENGINE connector PIN 15 and the sensor connector PIN 1: If not OK, restore the cable harness; if it is OK, replace the control unit. if there is 5V voltage at PIN 1, and with key set to ON, check the continuity to ground of the sensor connector PIN 3: If not OK, restore cable harness; if it is OK, replace the sensor.
AXONE: LOGIC ERRORS front cylinder air pressure sensor P0107 - signal not valid. Error cause According to the engine operation data (rpm, throttle, etc.) an average value for the intake pressure is estimated: if the value read deviates by a given percentage, this error is activated. The most frequent causes can be: abnormal resistance in the sensor circuit (for example, rusted terminals) or sensor with poor performance. Troubleshooting Check the filter casing large connector, the Marelli control unit connector and the sensor connector; if not OK, restore. If everything is OK, check that cable resistance between VEHICLE connector PIN 34 and sensor connector PIN 3 is a few tenths of an Ohm. If it is above that value, restore cable harness. Replace the sensor if it is correct. rear cylinder air pressure sensor P0108 - signal not valid. Error cause According to the engine operation data (rpm, throttle, etc.) an average value for the intake pressure is estimated: if the value read deviates by a given percentage, this error is activated. The most frequent causes can be: abnormal resistance in the sensor circuit (for example, rusted terminals) or sensor with poor performance. Troubleshooting Check the filter casing large connector, the Marelli control unit connector and the sensor connector; if not OK, restore. If everything is OK, check that resistance between VEHICLE connector PIN 5 and sensor connector PIN 3 is a few tenths of an Ohm. If it is above that value, restore cable harness. Replace the sensor if it is correct. Error for unexpected intake air in the front cylinder manifold P0210 - signal not valid. Error cause
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A small difference between the estimated pressure and the measured pressure has been detected: the measured pressure is higher than the estimated one (for example, cut or wrongly connected pipe between sensor and throttle body or a hole in the intake manifold).
Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean. Error for unexpected intake air in the rear cylinder manifold P0211 - signal not valid. Error cause A small difference between the estimated pressure and the measured pressure has been detected: the measured pressure is higher than the estimated one (for example, cut or wrongly connected pipe between sensor and throttle body or a hole in the intake manifold). Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean. Estimation error for front cylinder intake manifold pressure P0215 - pressure too high/pressure too low. Error cause A substantial difference between the estimated pressure and the measured pressure has been detected (for example, the pipe between sensor and throttle body is fully detached/ clogged or squashed). Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean: there is an evident defect in the intake and pressure reading systems. Estimation error for rear cylinder intake manifold pressure P0216 - pressure too high/pressure too low. Error cause A substantial difference between the estimated pressure and the measured pressure has been detected (for example, the pipe between sensor and throttle body is fully detached/ clogged or squashed). Troubleshooting
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Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean: there is an evident defect in the intake and pressure reading systems.
Pressure too low at front cylinder manifold error P0217 - signal not valid. A small difference between the estimated pressure and the measured pressure has been detected: the measured pressure is below the estimated one (for example, smeared throttle body). Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean. Pressure too low at rear cylinder manifold error P0218 - signal not valid. Error cause A small difference between the estimated pressure and the measured pressure has been detected: the measured pressure is below the estimated one (for example, smeared throttle body). Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean.
Electrical characteristics:
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Pin-out:
Resistance at 25: 2.05 kOhm +/- 100 Ohm Resistance at 60: 575 Ohm +/- 15 Ohm Resistance at 90: 230 Ohm +/- 5 Ohm
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: PARAMETERS Engine temperature Example value: 75 C In case of recovery, this value is set by the control unit. Engine Temp. before Recovery Example value: -40 C Value drawn from the signal read without taking into account any recovery: the value in the example refers to an open circuit. AXONE: ELECTRICAL ERRORS engine temperature sensor P0115 - open circuit, shorted to positive / shorted to negative. Error cause If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 45 of the ENGINE connector. If shorted to negative: voltage equal to zero has been detected at PIN 45 of the ENGINE connector. If the circuit is open, shorted to positive: check the sensor connector and the Marelli control unit connector. If they are OK, check sensor continuity: replace the sensor if not OK; if it is OK, check the continuity between the ENGINE connector PIN 45 and the sensor PIN 1: restore cable harness if there is not continuity; if it is OK, reconnect the control unit connector and, with key set to key ON, check the continuity between the sensor connector PIN 2 and ELE SYS - 45
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the vehicle ground connection: if it is correct, it means that the error cause is that the cable is short circuit to positive and it is necessary to restore the cable harness between the ENGINE PIN 45 and the sensor PIN 1; if there is no continuity with the ground connection, check the sensor connector and the Marelli control unit connector. If not OK, restore the cable harness. If OK, check continuity between the ENGINE connector PIN 35 and the sensor connector PIN 2: restore the cable harness if there is no continuity. If there is, it means that the control unit does not supply the ground connection and therefore should be replaced. Troubleshooting If shorted to negative, check sensor correct resistance: if resistance is null, replace the sensor; if resistance is correct, it means that the cable has ground connection: restore the cable harness. AXONE: LOGIC ERRORS engine temperature sensor P0116 - signal not valid. Error cause An excessive temperature variation has been detected: for example, the cause may be a contact resistance between the terminals. Troubleshooting Check the sensor connector and the ENGINE connector of the Marelli control unit.
NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty: then check through Axone if the temperature indicated is plausible in relation to the engine temperature. Check also that the sensor electrical characteristics are observed: replace the sensor if not OK; if it is OK, check the sensor connector and the Marelli control unit connector
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Electrical system
+/- 5% +/- 5%
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: PARAMETERS Air temperature Example value: 26 C In case of recovery, this value is set by the control unit. Air Temp. before Recovery Example value: -40 C Value drawn from the signal read without taking into account any recovery: the value in the example refers to an open circuit. AXONE: ELECTRICAL ERRORS air temperature sensor P0110 - open circuit, shorted to positive / shorted to negative. Error cause If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 63 of the ENGINE connector. If shorted to negative: voltage equal to zero has been detected at PIN 63 of the ENGINE connector. Troubleshooting If the circuit is open, shorted to positive: check the sensor connector and the Marelli control unit connector. If they are OK, check sensor continuity: replace the sensor if not OK; if it is OK, check continuity between the ENGINE connector PIN 63 and the sensor PIN 1: restore cable harness if there is not continuity; if it is OK, reconnect the control unit connector and, with key set to key ON, check the continuity between the sensor connector PIN 2 and the vehicle ground connection: if it is OK, it means that the error cause is that the cable is short circuit to positive and it is necessary to restore the cable harness between the ENGINE PIN 63 and the sensor PIN 1; check the sensor connector and the Marelli control unit connector. If not OK, restore the cable harness. If OK, check continuity between the ENGINE connector PIN 35 and the sensor connector PIN 2: restore the cable harness if there is not continuity.
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If there is, it means that the control unit does not supply the ground connection and therefore should be replaced. If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor; if resistance is correct, it means that the cable has ground connection: restore the cable harness. NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty: then check through Axone if the temperature indicated is plausible in relation to the ambient temperature. Check also that the sensor electrical characteristics are observed: replace the sensor if not OK; if it is OK, check the sensor connector and the Marelli control unit connector.
Lambda sensor
LAMBDA PROBE Function It tells the control unit whether combustion is lean or rich. Operation / Operating principle The Marelli injection control unit reads and interprets a voltage generated by the difference in oxygen content between the exhaust fumes and the ambient. It does not require an external supply source but, in order to work properly, it should reach a high operating temperature: that is why there is a heating circuit inside. Level in wiring diagram:Lambda probe Location: on the vehicle: exhaust pipe connector: near the probes
Electrical characteristics: Oxygen probe with preheating circuit (power 7W) It generates voltage within: 0 - 1000 mV Heater circuit: continuity (7 - 9 Ohm at ambient temperature) Pin-out:
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Electrical system
1. Sensor signal + (black wire) 2. Sensor signal - (grey wire) 3. Heater ground connection (white) 4. Heater power supply (white) THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: PARAMETERS Lambda probe Example value: 0 - 1000 mV If there is a short circuit at + 5 V or above, the lambda probe parameter is not equal to the value read by the control unit; a recovery value is displayed instead. Lambda sensor correction Example value: 1.00 In closed loop, the value must be close to 1.00 (values not within the 0.90 - 1.10 interval indicate a fault): for example, value 0.75 corresponds to +25% with respect to the reference injection time; 1.25 corresponds to -25%. In an open circuit, the lambda probe signal is too low. Therefore, the control unit takes it as a lean combustion condition and will try to enrich it. The value read will be 0.75: once this correction has been tried, the value shifts to 1.00 fixed and the Lambda probe error is signalled. AXONE: STATUSES Lambda Example value:Start-up_Lean_Rich_Fault due to rich value_Fault due to lean value If the probe connector is removed (voltage almost equal to zero), the status is Fault due to lean value Lambda check Example value: Open loop/Closed loop/Rich in closed loop/Lean in closed loop/enriched Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion as close as possible to the stoichiometric value. AXONE: ACTIVATIONS Lambda probe heating The auxiliary injection relay (No. 42 in the wiring diagram, placed under fuel tank, right side, third relay starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised and the heating circuit is closed to ground 5 times (pin 3 of the lambda probe connector). The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation. ELE SYS - 49
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AXONE: ELECTRICAL ERRORS Lambda probe P0130 - short circuit to positive. Error cause Excessive voltage (battery voltage) has been detected at PIN 43 of the ENGINE connector. Caution: the "lambda probe" parameter is not the real value that is read; a recovery value is displayed instead. Troubleshooting If shorted to positive: with key set to ON, disconnect the sensor connector and measure PIN 1 voltage on the cable harness side (grey cable): if there is voltage (5 or 12 V), restore the cable harness; if there is not, replace the lambda probe. Lambda probe heating P0135 - short circuit to positive / open circuit, short circuit to negative. Error cause If shorted to positive: excessive voltage has been detected at PIN 32 of the ENGINE connector. If the circuit is open, short circuit to negative: voltage equal to zero has been detected at PIN 32 of the ENGINE connector. Troubleshooting If shorted to positive: disconnect the probe connector and check the sensor correct resistance: replace the sensor if not OK; if it is OK, restore the cable harness. if the circuit is open, short circuit to negative: check the continuity from probe connector (PIN 3 and 4) towards the probe: if not OK, replace the probe; if it is correct, check the sensor connector and the Marelli control unit connector. If not OK, restore. If OK, and with key set to ON and sensor connector disconnected, check if there is battery voltage at PIN 4: if there is not, check the red/black cable between the probe connector and the auxiliary injection relay (No. 42 in the wiring diagram, located under fuel tank, right side, third relay starting from the front; however, the identification of the relay with the colour of the cables). If there are also coil and injector errors, check the relay and its excitation and power line; if there is voltage at PIN 4, check the grey/blue cable earth insulation (PIN 3): if not OK, restore the cable harness. If it is OK, check the continuity of the grey/blue cable (between the sensor connector PIN 3 and the ENGINE PIN 32) and restore the cable harness. AXONE: LOGIC ERRORS Lambda probe P0134 - voltage without variation. Error cause An abnormal behaviour of the voltage at PIN 43 of the ENGINE connector has been detected: the voltage, that should vary over time, keeps a constant value instead. Troubleshooting
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Electrical system
Check circuit continuity from probe connector (PIN 1 and PIN 2) toward the probe: replace the lambda probe if there is no continuity; if there is continuity, check the sensor connector and the Marelli control unit connector: If not OK, restore. If OK, check continuity between the ENGINE connector PIN 43 and PIN 60 and restore the cable harness.
CAUTION
IN CASE THE Lambda sensor correction PARAMETER, WITH ENGINE AT IDLE AND H2O T >90 C, WHICH IS NOT WITHIN THE 0.9 - 1.1 RANGE, WITHOUT ERRORS, CHECK: - IF < 0.9, THE PROBE READS LEAN COMBUSTION CONDITIONS AND THE CONTROL UNIT INCREASES INJECTION TIME; CAUSES: CHECK FOR INCORRECT AIR INTAKE, LITTLE PETROL, RUSTY TERMINAL CONTACTS, DEFECTIVE PROBE. - IF > 1.1, THE PROBE READS RICH COMBUSTION CONDITIONS AND THE CONTROL UNIT REDUCES INJECTION TIME; CAUSES: LITTLE AIR, EXCESSIVE PETROL, DEFECTIVE PROBE.
Injector
INJECTOR Function To supply the correct amount of petrol at the right timing. Operation / Operating principle Injector coil is excited for the petrol passage to open. Level in wiring diagram:Coils and injectors. Location: on the vehicle: inside the filter casing connector: on injector
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: PARAMETERS Front cylinder injection time Rear cylinder injection time AXONE: ACTIVATIONS Front injector The auxiliary injection relay (No. 42 in the wiring diagram, placed under fuel tank, right side, third relay starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is ELE SYS - 51
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energised for 5 seconds and the grey/green cable of the injector is closed to ground for 4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation. Rear injector The auxiliary injection relay (No. 42 in the wiring diagram, placed under fuel tank, right side, third relay starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the grey/red cable of the injector is closed to ground for 4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation. AXONE: ELECTRICAL ERRORS Front cylinder injector P0201 - short circuit to positive / short circuit to negative / open circuit. Error cause If shorted to positive: excessive voltage has been detected at PIN 50 of the ENGINE connector. If shorted to negative: no voltage has been detected. If the circuit is open: an interruption has been detected.
Troubleshooting if shorted to positive: disconnect the injector connector, set key to ON, activate the component with Axone and check the voltage on the filter casing grey/green cable on the filter casing small connector towards the Marelli control unit: if there is voltage, restore the cable harness between the filter casing connector and the Marelli control unit. If there is no voltage, reconnect the connector and check if there is voltage at PIN -: if there is voltage, restore the filter casing cable harness. If there is not, replace the sensor. if shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the grey/green cable: if there is, restore the cable harness between the filter casing connector and the Marelli control unit; if there is not, reconnect the connector and disconnect the injector connector and check if there is a ground connection on PIN -: if there is voltage, restore the filter casing cable harness. If there is not, replace the injector. the circuit is open: check the component correct electrical characteristic: if it is not correct, replace the component; if it is correct, check the filter casing small connector, the connector on the component and the Marelli control unit connector: If not OK, restore; if OK, check cable continuity between ENGINE PIN 50 and component PIN - and restore the cable harness. Front cylinder injector P0202 - See front injector Error cause ELE SYS - 52
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Electrical system
If shorted to positive: excessive voltage has been detected at PIN 34 of the ENGINE connector. If shorted to negative: no voltage has been detected. If the circuit is open: an interruption has been detected.
Troubleshooting if shorted to positive: disconnect the injector connector, set key to ON, activate the component with Axone and check the voltage on the filter casing grey/green cable on the filter casing small connector towards the Marelli control unit: if there is voltage, restore the cable harness between the filter casing connector and the Marelli control unit. If there is no voltage, reconnect the connector and check if there is voltage at PIN -: if there is voltage, restore the filter casing cable harness. If there is not, replace the sensor. if shorted to negative: disconnect the injector connector, set the key to key ON and check if there is a ground connection on the grey/red cable: if there is, restore the cable harness between the filter casing connector and the Marelli control unit; if there is not, reconnect the connector and disconnect the injector connector and check if there is a ground connection on PIN -: if there is voltage, restore the filter casing cable harness. If there is not, replace the injector. the circuit is open: check the component correct electrical characteristic: if it is not correct, replace the component; if it is correct, check the filter casing small connector, the connector on the component and the Marelli control unit connector: If not OK, restore. If OK, check cable continuity between the ENGINE PIN 34 and component PIN - and restore the cable harness.
Coil
COIL Function Spark generation. Operation / Operating principle Inductive discharge system. Level in wiring diagram:coils and injectors. Location: on the vehicle: on the cylinder head connector (if available): -
Electrical characteristics: Primary circuit resistance: approx. 1 Ohm at 20C between PIN 1 and 3.
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Secondary circuit resistance: MOhm value range (with positive probe on coil).
Pin-out: 1. Supply + batt V 2. Secondary circuit ground connection 3. Activation from control unit
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: PARAMETERS Rear coil ignition advance Front coil ignition advance AXONE: STATUSES AXONE: ACTIVATIONS Front coil The auxiliary injection relay (No. 42 in the wiring diagram, placed under fuel tank, right side, third relay starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the sky blue/orange cable of the coil is closed to ground for 2 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation. Rear coil The auxiliary injection relay (No. 42 in the wiring diagram, placed under fuel tank, right side, third relay starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the sky blue/green cable of the coil is closed to ground for 2 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation. ELE SYS - 54
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AXONE: ELECTRICAL ERRORS Lambda probe P0130 - short circuit to positive / circuit, short circuit to negative Error cause If shorted to positive: excessive voltage has been detected at PIN 17 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 17 of the ENGINE connector. Troubleshooting if shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with Axone and check voltage at connector PIN 3: if there is voltage, restore the cable harness; if voltage = 0, replace the coil. Open circuit, short circuit to negative: check the coil connector and the Marelli control unit connector. If not OK, restore; if everything is OK, check cable continuity between the two cable terminals. If there is no continuity, restore the cable harness; if there is cable continuity, with key set to ON, check the cable earth insulation (from coil connector or control unit connector). If not OK, restore the cable harness. Rear coil P0352- short circuit to positive / open circuit, short circuit to negative. Error cause If shorted to positive: excessive voltage has been detected at PIN 19 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 19 of the ENGINE connector. Troubleshooting If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with Axone and check voltage at connector PIN 3: if there is voltage, restore the cable harness; if voltage = 0, replace the coil. If the circuit is open, short circuit to negative: check the coil connector and the Marelli control unit connector. If not OK, restore; if everything is OK, check cable continuity between the two cable terminals. If there is no continuity, restore the cable harness; if there is cable continuity, with key set to ON, check the cable earth insulation (from coil connector or control unit connector). If not OK, restore the cable harness. AXONE: LOGIC ERRORS -
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Throttle body
THROTTLE BODY Function To inform the throttle control unit the position of the two throttle valves and to drive them both. Operation / Operating principle All the unit internal components (potentiometer and electric motor) are contactless; therefore, no electrical diagnosis is possible for the throttle body, only for the circuits connected to it. Throttle body activation takes place every time the key is set to ON: correct activation is indicated when the stop lights turn on. If during activation, the engine is started, the activation is not completed and the stop lights do not turn on. Every 150 key-ONs, however, the throttle valves are forced to activation. If start-up is attempted during this activation (which requires 3 seconds), the engine will not start. Level in wiring diagram: throttle control unit. Location: Pin-out: 1. potentiometer signal: 1 2. supply voltage + 5V 3. throttle valve control (+) 4. potentiometer signal: 2 5. throttle valve control (+) 6. ground connection
CAUTION
on the vehicle: inside the filter casing connector: on the throttle body
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: PARAMETERS Front throttle Potentiometer 1 (voltage) Example value: 800 mV The value in the example refers to engine conditions with key set to ON. Front throttle Potentiometer 2 (voltage) Example value: 3878 mV ELE SYS - 56
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The value in the example refers to engine conditions with key set to ON. Rear throttle Potentiometer 1 (voltage) Example value: 780 mV The value in the example refers to engine conditions with key set to ON. Rear throttle Potentiometer 2 (voltage) Example value: 3756 mV The value in the example refers to engine conditions with key set to ON. Front throttle Potentiometer 1 - 2 (degrees) / Rear throttle Potentiometer 1 - 2 (degrees) Example value: 6.5 With key set to ON, the throttle is kept in position by the springs (approximately 5 - 7). After the engine starts up at idle, the throttle is kept close to the mechanical minimum (above or equal to 0.5). When the gear is not engaged, at approx. 6000 rpm, throttles open very little because the requested torque is too low (approximately 5 - 7). Front / rear cylinder throttle correction Example value: 0.0 For example, if there is a hole in the intake manifold, the pressure read is different from the pressure estimated by the control unit and the system tries to reach an "estimated" situation by opening the throttle a little bit more; therefore, this parameter takes a value different from zero: an acceptable value should be between -0.7 and +0.7. Front cylinder Limp home position / Rear cylinder Limp home position Example value: 800 mV / 780 mV Voltage stored in the control unit corresponding to the throttle Limp home position. Front throttle lower position / Rear throttle lower position Example value: 502 mV / 492 mV Voltage stored in the control unit corresponding to the throttle mechanical minimum position. AXONE: STATUSES Throttle Self-learning Example value:carried out/not carried out Indicates whether or not the autodetection process has been carried out through the diagnosis instrument. AXONE: ACTIVATIONS AXONE: ELECTRICAL ERRORS Potentiometer 1 sensor, front throttle position P0120 Example value:short circuit to positive/ open circuit, short circuit to negative Error cause
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If shorted to positive: excessive voltage has been detected at PIN A6 of the throttle control unit. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN A6 of the throttle control unit.
Troubleshooting if shorted to positive: check the value shown by the parameter of the front throttle Potentiometer 1 (voltage): disconnect the left connector and see the value displayed by Axone: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle body if the voltage drops to zero. if the circuit is open, short circuit to negative: check the throttle body connector and the throttle valve connector. If not OK, restore; if everything is OK, check circuit continuity between the two terminals. If not OK, restore the cable harness; if OK, check the circuit earth insulation (from throttle sensor connector or control unit connector). If it is earth insulated, check that there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body. Potentiometer 2 sensor, front throttle position P0122 Example value:short circuit to positive/ open circuit, short circuit to negative Error cause If shorted to positive: excessive voltage has been detected at PIN A5 of the throttle control unit. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN A5 of the throttle control unit. Troubleshooting if shorted to positive: check the value shown by the parameter of the front throttle Potentiometer 2 (voltage): disconnect the left connector and see the value displayed by Axone: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle body if the voltage drops to zero. if the circuit is open, short circuit to negative: check the throttle body connector and the throttle valve connector. If not OK, restore; if everything is OK, check circuit continuity between the two terminals. If not OK, restore the cable harness; if OK, check the circuit earth insulation (from throttle sensor connector or control unit connector). If it is earth insulated, check that there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body. Potentiometer 1 sensor, rear throttle position P0125 Example value:short circuit to positive/ open circuit, short circuit to negative Error cause
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If shorted to positive: excessive voltage has been detected at PIN B6 of the throttle control unit. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN B6 of the throttle control unit.
Troubleshooting if shorted to positive: check the value shown by the parameter of the Front throttle Potentiometer 1 (voltage): disconnect the left connector and see the value displayed by Axone: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle body if the voltage drops to zero. if the circuit is open, short circuit to negative: check the throttle body connector and the throttle valve connector. If not OK, restore; if everything is OK, check circuit continuity between the two terminals. If not OK, restore the cable harness; if OK, check the circuit earth insulation (from throttle sensor connector or control unit connector). If it is earth insulated, check that there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body. Potentiometer 2 sensor, rear throttle position P0127 Example value:short circuit to positive/ open circuit, short circuit to negative Error cause If shorted to positive: excessive voltage has been detected at PIN B5 of the throttle control unit. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN B5 of the throttle control unit. Troubleshooting if shorted to positive: check the value shown by the parameter of the Rear throttle Potentiometer 2 (voltage): disconnect the left connector and see the value displayed by Axone: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle body if the voltage drops to zero. if the circuit is open, short circuit to negative: check the throttle body connector and the throttle valve connector. If not OK, restore; if everything is OK, check circuit continuity between the two terminals. If not OK, restore the cable harness; if OK, check the circuit earth insulation (from throttle sensor connector or control unit connector). If it is earth insulated, check that there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body. Front throttle supply voltage during self-learning P0164 Example value:low supply voltage Error cause
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The throttle power supply is too low to carry out the autodetection test correctly (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status.
Troubleshooting The throttle test is not carried out when the key is set to ON because the test could show unreal errors (because the voltage is too low). Voltage is detected by the Marelli control unit. Front throttle control circuit P0166 Example value:short circuit to positive / short circuit to negative / open circuit, overcurrent, excessive internal temperature. Error cause If shorted to positive: excessive voltage has been detected at PIN C1 of the throttle control unit connector. If shorted to negative: no voltage has been detected. If the circuit is open: an interruption has been detected. Troubleshooting if shorted to positive: disconnect the throttle body connector, set key to ON and check voltage at PIN 3: if the voltage read is higher or equal to 5V, there is a short circuit on the cable harness; replace the throttle body if the voltage is null if shorted to negative: disconnect the throttle body connector, set the key to ON and check if PIN 3 is in continuity with the vehicle ground connection: if it is, there is a short circuit in the cable ground connection; if it is not, replace the throttle body. open circuit, overcurrent, excessive inside temperature: check the throttle body connector and the throttle control unit connector. If not OK, restore. If everything is OK, disconnect the throttle body connector (PIN 3) and the throttle control unit connector (C1) and check the circuit continuity between the two terminals; if there is no continuity, restore the cable harness. If there is continuity, with the throttle body connector connected, check that the resistance, from the throttle control unit connector, between PIN A1 and C1 is within 1 and 2.5 Ohm; if it is not, replace the throttle body; if it is, check that the throttle body is not mechanically blocked: if blocked, solve the problem and replace the body; if it is not, replace the throttle control unit. Rear throttle supply voltage during self-learning P0184 Example value:low supply voltage Error cause The throttle power supply is too low to carry out the autodetection test correctly (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting
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The throttle test is not carried out when the key is set to ON because the test could show unreal errors (because the voltage is too low). Voltage is detected by the Marelli control unit.
Rear throttle control circuit P0186 Example value:short circuit to positive / short circuit to negative / open circuit, overcurrent, excessive internal temperature. Error cause If shorted to positive: excessive voltage has been detected at PIN 8A of the throttle control unit connector. If shorted to negative: no voltage has been detected. If the circuit is open, there is overvoltage or excessive internal temperature: an interruption or excessive ampere input or control unit overheating has been detected. Troubleshooting if shorted to positive: disconnect the throttle body connector, set key to ON and check voltage at PIN 3: if the voltage read is higher or equal to 5V, there is a short circuit on the cable harness; replace the throttle body if the voltage is null. if shorted to negative: disconnect the throttle body connector, set the key to ON and check if PIN 3 is in continuity with the vehicle ground connection: if it is, there is a short circuit in the cable ground connection; if it is not, replace the throttle body. open circuit, overvoltage, excessive inside temperature: check the throttle body connector and the throttle control unit connector. If not OK, restore. If everything is OK, disconnect the throttle body connector (PIN 3) and the throttle control unit connector (C8) and check the circuit continuity between the two terminals; if there is no continuity, restore the cable harness. If there is continuity, with the throttle body connector connected, check that the resistance, from the throttle control unit connector, between PIN A8 and C8 is within 1 and 2.5 Ohm; if it is not, replace the throttle body; if it is, check that the throttle body is not mechanically blocked: if blocked, solve the problem and replace the body; if it is not, replace the throttle control unit. AXONE: LOGIC ERRORS Potentiometer 1 sensor, front throttle position P0121 - signal not valid. Error cause Signal not within the expected value drawn according to the values of the intake pressure.
Troubleshooting Check the parameter of the Potentiometer 1 Front throttle (voltage) to get which signal the control unit receives and to compare it to the Potentiometer 1 Rear throttle (voltage). Check the throttle body connector as well as the throttle control unit connector. Check that cable resistance between the throttle body connector (PIN 1) and the throttle control unit (PIN 6A)
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is a few tenths of an Ohm. If this is not the case, restore the cable harness. If the value is correct, replace the complete throttle body. Potentiometer 2 sensor, front throttle position P0123 - signal not valid. Error cause Signal not within the expected value drawn according to the values of the intake pressure.
Troubleshooting Check the parameter of the Potentiometer 1 Front throttle (voltage) to get which signal the control unit receives and to compare it to the Potentiometer 2 Rear throttle (voltage). Check the throttle body connector as well as the throttle valve control unit connector. Check that cable resistance between the throttle body connector (PIN 4) and the throttle control unit (PIN 5A) is a few tenths of an Ohm. If this is not the case, restore the cable harness. If the value is correct, replace the complete throttle body. Front throttle valve position sensors P0124 - illogical signal. Error cause Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an abnormal resistance in one of the two circuits. Troubleshooting Check the throttle body connector as well as the throttle control unit connector. Check that cable resistance between the throttle body connector (PIN 1) and the throttle control unit (PIN 6A) is a few tenths of an Ohm. Check that cable resistance between the throttle body connector (PIN 4) and the throttle control unit (PIN 5A) is a few tenths of an Ohm. If one of the two is different, restore the cable harness. If correct, replace the complete throttle body. Potentiometer 1 sensor, rear throttle position P0126 - signal not valid. Error cause Signal not within the expected value drawn according to the values of the intake pressure.
Troubleshooting Check the parameter of the Potentiometer 1 Rear throttle (voltage) to get which signal the control unit receives and to compare it to the Potentiometer 1 Front throttle (voltage). Check the throttle body connector as well as the throttle control unit connector. Check that cable resistance between the throttle body connector (PIN 1) and the throttle control unit (PIN 6B) is a few tenths of an Ohm. If this is not the case, restore the cable harness. If the value is correct, replace the complete throttle body. Potentiometer 2 sensor, rear throttle position P0128 - signal not valid. Error cause
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Signal not within the expected value drawn according to the values of the intake pressure.
Troubleshooting Check the parameter of the Potentiometer 2 Rear throttle (voltage) to get which signal the control unit receives and to compare it to the Potentiometer 2 Front throttle (voltage). Check the throttle body connector as well as the throttle control unit connector. Check that cable resistance between the throttle body connector (PIN 4) and the throttle control unit (PIN 5B) is a few tenths of an Ohm. If this is not the case, restore the cable harness. If the value is correct, replace the complete throttle body. Rear throttle position sensors P0129 - illogical signal. Error cause Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an abnormal resistance in one of the two circuits. Troubleshooting Check the throttle body connector as well as the throttle control unit connector. Check that cable resistance between the throttle body connector (PIN 1) and the throttle control unit (PIN 6B) is a few tenths of an Ohm. Check that cable resistance between the throttle body connector (PIN 4) and the throttle control unit (PIN 5B) is a few tenths of an Ohm. If one of the two is different, restore the cable harness. If correct, replace the complete throttle body. Front throttle Limp Home autodetection P0160 - test failed. Error cause Throttle position, kept by the springs, not within the expected range (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting Check if the throttle body and the intake duct are clean. If they are, replace the throttle body.
Front throttle mechanical springs autodetection P0161 - test failed. Error cause Return time of the throttle, kept in position by the springs, not within the expected limits: the causes can be a deterioration of the performance of the springs or excessive throttle friction (at each key ON). Troubleshooting. Check if the throttle body and the intake duct are clean. If they are, replace the throttle body.
Front throttle minimum mechanical position autodetection P0162 - test failed. Error cause Position of the throttle stop not within the expected range (at each key ON).
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Check if the throttle body and the intake duct are clean. If they are, replace the throttle body.
Detection of front throttle valve Recovery conditions (air T,water T) P0163 - possible presence of ice. Error cause A correct throttle rotation cannot be detected given low ambient and engine temperatures: some ice may have formed in the duct (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting Check that the throttle body is clean and that there is no ice or condensation in the intake duct. If they are, replace the throttle body. Front throttle first self-learning NOT performed P0165 - test not carried out. Error cause The first throttle self-learning process has not been successful or has not been carried out. The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting. Delete errors hindering throttle self-learning.
Front throttle position error P0167 - misalignment between control and activation. Error cause The throttle mechanical control may be damaged.
Rear throttle Limp Home autodetection P0180 - test failed. Error cause Throttle position, kept by the springs, not within the expected range (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting Check if the throttle body and the intake duct are clean. If they are, replace the throttle body.
Rear throttle mechanical spring autodetection P0181 - test failed. Error cause Return time of the throttle, kept in position by the springs, not within the expected limits: the causes can be a deterioration of the performance of the springs or excessive throttle friction (at each key ON). Troubleshooting. Check if the throttle body and the intake duct are clean. If they are, replace the throttle body.
Rear throttle minimum mechanical position autodetection P0182 - test failed. ELE SYS - 64
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Error cause Position of the throttle stop not within the expected range (at each key ON).
Troubleshooting. Check if the throttle body and the intake duct are clean. If they are, replace the throttle body.
Detection of the rear throttle Recovery conditions (air T, water T) P0183 - possible presence of ice. Error cause A correct throttle rotation cannot be detected given low ambient and engine temperatures: some ice may have formed in the duct (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting Check that the throttle body is clean and that there is no ice or condensation in the intake duct. If they are, replace the throttle body. Rear throttle first self-learning NOT performed P0185 - test not carried out. Error cause The first throttle self-learning process has not been successful or has not been carried out. The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting. Delete errors hindering throttle self-learning.
Rear throttle position error P0187 - misalignment between control and activation. Error cause The throttle mechanical control may be damaged.
RESET PROCEDURE If the Marelli control unit or the throttle body is replaced, do not start the engine within the 3 seconds after the key is set to ON; during this time the control unit carries out the throttle self-learning process: then make sure that the throttle self-learning status reads: carried out. If the indication is "Not carried out", delete any possible errors present in the vehicle. Carry out Throttle self-learning process on the adjustable parameters screen page (screwdriver and hammer), and check again that the throttle selflearning status reads: carried out.
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Instrument panel Error DSB 07 Error cause An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. This error is signalled by the bulb icon and the general warning light turns on as well. Troubleshooting Check the sensor connector and the instrument panel connector (PIN 17): If not OK, restore. If OK, check the continuity of the purple cable between the sensor connector and the instrument panel connector PIN 17: if not OK, restore the cable harness; if OK, replace the sensor.
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Error DSB 08 Error cause An oil sensor failure is signalled when, with engine running, it is detected that the sensor circuit is closed. This error is signalled by the bulb icon and the general warning light turns on as well. Troubleshooting Check if oil pressure is low with the specific gauge.
Neutral sensor
GEAR IN NEUTRAL SENSOR Function it tells the gear position to the control unit: in neutral or in gear. Operation / Operating principle for gear in neutral, the circuit is closed to ground connection: then, via CAN, the control unit sends the signal to the instrument panel which turns on the neutral speed warning light. Level in wiring diagram:start-up enabling switches Location: on the vehicle: left side of the vehicle, near flywheel cover connector: upper part of the flywheel cover Electrical characteristics: gear in neutral: closed circuit (continuity) gear engaged: open circuit (infinite resistance) Pin-out: 1. Voltage 12V
CAUTION
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BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: STATUSES Gear in neutral Example value:yes/no AXONE: NOTES Indication on the instrument panel always gear engaged: check the correct position of the cable terminals on the connector and the correct connection of the cables on the terminals. If they are not correct, restore the cable harness; if correct, disconnect the connector and, with gear in neutral, check continuity to terminal ground connection, sensor side: if there is no continuity, replace the sensor (after checking cable continuity on the sensor side and the correct mechanical position). If there is, check the correct position of the terminal on the control unit connector and the correct connection of the cables on the terminals. If they are not correct, restore the cable harness; if OK, check the cable continuity between the sensor connector and ENGINE connector PIN 16: if there is no continuity, restore the cable harness. If there is, replace the instrument panel if the vehicle performance is correct (the engine starts with gear in neutral but the neutral warning light is off) or replace the control unit if the vehicle performance is not correct (the engine does not start with gear in neutral). Indication on the instrument panel always gear in neutral: disconnect the terminals from the sensor and check if there is continuity with ground connection at PIN toward the sensor, with gear engaged: if there is continuity, replace the sensor. If it is insulated from the ground connection, it means that the green/black cable from sensor PIN 1 to ENGINE connector PIN 16 is short circuited to ground: restore the cable harness
Electrical characteristics:
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Pin-out:
Clutch pulled: closed circuit (continuity) Clutch released: open circuit (infinite resistance)
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: STATUSES Clutch Example value:Indefinite - released - pulled The statuses regularly viewed are Released / Pulled Troubleshooting: Indication on Axone always Released: check the correct position of the cable terminals on the connector and the correct connection of the cables on the terminals. If they are not correct, restore the cable harness; if correct, disconnect the two terminals from the sensor and, with key set to ON, check continuity to ground connection of PIN 2: if there is no continuity, restore the cable harness; if there is, replace the sensor Indication on Axone always Pulled: disconnect the terminals from the sensor and check if there is continuity between the two PINS, with clutch released: if there is continuity, replace the sensor. If the circuit is open, it means that the brown/purple cable from sensor PIN 1 to ENGINE connector PIN 50 is short circuit to ground: restore the cable harness
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BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: STATUSES Side stand Example value:up/down Indication on Axone always down: check the connector: if not OK, restore; if it is OK, disconnect the two terminals from the sensor and check continuity to ground of PIN 1: if there is no continuity, restore the cable harness; if there is, replace the sensor. Indication on Axone always up: disconnect the terminals from the sensor and check if there is continuity between the two PINS, with stand down: if there is continuity, replace the sensor; if the circuit is open, it means that the brown/green cable from sensor PIN 2 to ENGINE connector PIN 6 is short circuit to ground: restore the cable harness.
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Electrical characteristics: Sensor in vertical position: open circuit (resistance: 62 kOhm) Sensor inverted: closed circuit (continuity) Pin-out: 1. Ground connection 2. Voltage 5V
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: PARAMETERS Fall sensor Example value: Normal / Tip over Indication on Axone always Normal, even when the sensor is inverted: disconnect the connector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: if there is no continuity, replace the sensor; if there is, check the connector. If not OK, restore the cable harness; if OK, check continuity to ground of PIN 1: if there is no continuity, restore the cable harness; if there is, with key set to ON, check if there is 5V voltage at PIN 2. If there is not, check the Marelli control unit connector (ENGINE connector PIN 8). Indication on Axone always Tip over: disconnect the connector and check if there is continuity between the two PINS when the sensor is in vertical position: if there is continuity, replace the sensor; if there is ELE SYS - 71
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not, it means that, with key set to ON, there is no 5V voltage at PIN 2: restore the cable harness whose pink/white cable will be short circuit to ground
Electrical characteristics: Pin-out: 1. Voltage 5V 2. Ground connection AXONE: ELECTRICAL ERRORS INSTRUMENT PANEL DSB 06 Error cause The oil sensor failure is signalled when it is detected that the sensor circuit is open or short circuit to positive. Troubleshooting Check the sensor connector and the instrument panel connector (PINS 10 and 30): If not OK, restore; if OK, check the continuity of the pink cable between the sensor connector and the instrument panel connector PIN 10: if not OK, restore the cable harness; if OK, check the correct sensor resistance: if not OK, replace the sensor; if it is OK, check the continuity of the yellow/black cable between the sensor connector and the instrument panel connector PIN 30: If not OK, restore the cable harness; if OK, with key set to ON, check if there is voltage at the sensor connector PIN 1: if there is no voltage, replace the instrument panel; if there is approximately 12V, restore the cable harness (there is a short circuit in the battery). ELE SYS - 72 Resistance at 0C: 32.5 kOhm +/- 5% Resistance at 25C: 10.0 kOhm +/- 5%
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If there is 5V voltage, connect a 10 kOhm resistance to sensor connector PIN 1 and to the vehicle ground connection: if, with key set to ON, the voltage measured upstream the resistance decreases, replace the instrument panel. If voltage continues to be approximately 5V, restore the pink cable (there is a short circuit at + 5V) Notes If a short circuit to ground is detected at instrument panel connector PIN 10, the display will shown a full scale indication ????? of air temperature. Check the earth insulation of the sensor connector pink cable: if there is a connection, restore the cable harness; if it is earth insulated, check that sensor resistance is correct: if not OK, replace the sensor; if it is OK, replace the instrument panel
AXONE: STATUSES Fan relay Example value:on/off AXONE: ACTIVATIONS Fan: The fan relay (No. 44 in the wiring diagram, placed under fuel tank, left side, first front relay; CHECK, however, the identification of the relay with the colour of the cables) is energised for 10 seconds. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation. AXONE: ELECTRICAL ERRORS Cooling fan relay P0480 - short circuit to positive / short circuit to negative / open circuit. Error cause ELE SYS - 73
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If shorted to positive: excessive voltage has been detected at PIN 54 of the VEHICLE connector. If shorted to negative: short circuit to ground detected. If the circuit is open: interrupted circuit detected. Excessive voltage can only be detected after the fan relay gets activated.
Troubleshooting If shorted to positive: check the relay electrical specifications are correct by disconnecting it from the cable harness. If they are not correct, replace the relay; if correct, restore the cable harness (pink/blue cable). If shorted to negative: check the relay electrical specifications are correct by disconnecting it from the cable harness. If they are not correct, replace the relay; if correct, restore the cable harness (pink/blue cable). If the circuit is open: check the relay connector and the Marelli control unit VEHICLE connector: If not OK, restore; if OK, restore the cable harness (red/blue cable).
RUN/STOP switch
Run / stop switch Function It tells the control unit if the driver wishes to enable engine start-up or to keep the engine running. Operation / Operating principle If the driver wants to shut off the engine or to disable engine start-up, the switch should be open, i.e. the Marelli control unit should not detect voltage at VEHICLE connector PIN 2. Level in wiring diagram:Start-up enabling switches. Location:
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on the vehicle: right light switch connector: inside the rubber protection located between the water radiator and the fuel tank, to the right.
Electrical characteristics: STOP position: the circuit is open RUN position: closed circuit (continuity) Pin-out: 1. Yellow/grey cable: 2. Red/black cable: Voltage 12V
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: PARAMETERS AXONE: STATUSES Run / stop switch Example value:Run/Stop Indication on Axone always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity toward the switch of the two yellow/grey and red/black cables: if there is no continuity, replace the sensor; if there is, check the connector. If not OK, restore the cable harness; if it is OK, with key set to ON, check if there is voltage to the red/black cable: if there is no voltage, restore the cable harness; if there is, check the yellow/grey cable earth insulation: if there is continuity to ground, restore the cable harness; if it is correct, take the key to OFF and check the VEHICLE connector is in good conditions and the continuity of the grey/yellow cable between the sensor in question and the VEHICLE connector PIN 26: if not OK, restore the cable harness; if OK, replace the Marelli control unit. Indication on Axone always RUN: disconnect the connector and, with the switch set to STOP, check if there is continuity between the two cables of the switch: if there is continuity, replace the switch; if there is not, it means that, with key set to ON, the yellow/grey cable is short circuit to positive: restore the cable harness.
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Level in wiring diagram:throttle control unit Location: on the vehicle: inside the filter casing connector: on the control unit
See also
Throttle control unit
Connectors ECU
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12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
NOTE
Specification Side stand input "start engine" input Clutch sensor input Fall sensor input Gear/neutral input Start-up control output Serial line K for diagnosis Auxiliary injection relay control output Front coil control output Rear coil control output Front injector control output Rear injector control output Air temperature sensor input Front throttle reset output Rear throttle reset output "Engine stop" input Electric fan relay control output STOP light relay control output Lambda heater control output Lambda sensor input (+) Lambda sensor input (-) Purge Canister valve control output (optional) Control unit direct power supply Power ground connection 1 Power ground connection 2 Power ground connection 3 Power ground connection 4 Reference voltage output +5V: tracks A-C and pressure sensor Reference voltage output +5V: tracks B-D and speed sensor Analogue ground connection 1 Analogue ground connection 2 CAN H Line (high speed) CAN L Line (high speed)
Desc./Quantity Vehicle connector: 6 Vehicle connector: 14 Vehicle connector: 50 Engine connector: 8 Engine connector: 16 Engine connector: 2 Vehicle connector: 10 Vehicle connector: 62 Engine connector: 17 Engine connector: 19 Engine connector: 50 Engine connector: 34 Engine connector: 63 Vehicle connector: 56 Vehicle connector: 55 Vehicle connector: 26 Vehicle connector: 54 Vehicle connector: 59 Engine connector: 32 Engine connector: 43 Engine connector: 60 Engine connector: 51 Vehicle connector: 16 Engine connector: 21 Engine connector: 5 Engine connector: 22 Engine connector: 6 Engine connector: 15 Engine connector: 13 Engine connector: 35 Vehicle connector: 46 Engine connector: 36 Vehicle connector: 51 Vehicle connector: 20
THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR.
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NOTE
THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR.
ELE SYS - 78
SL 750 SHIVER
Electrical system
Specification 1A - Front throttle motor control (-) 2A - CAN L 3A - Voltage for front throttle potentiometers (+ 5 V) 4A - Key input 5A - Input for front throttle potentiometer 2 signal 6A - Input for front throttle potentiometer 1 signal 7A - Front throttle reset signal input 8A - Rear throttle motor control (+) 1B - Battery power supply input 2B - CAN H 3B - Voltage for rear throttle potentiometers (+ 5 V) 4B - Firmware reprogramming power supply 5B - Input for rear throttle potentiometer 2 signal 6B - Input for rear throttle potentiometer 1 signal 7B - Rear throttle reset signal input 8B - Battery power supply input 1C - Front throttle motor control (+) 2C - Ground connection 3C - Ground connection 4C - Ground connection 5C - Ground connection 6C - Ground connection 7C - Ground connection 8C - Rear throttle motor control (-)
Front throttle body PIN: 3 Front throttle body PIN: 6 Rear throttle body PIN: 6
THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR.
ELE SYS - 79
Electrical system
SL 750 SHIVER
Dashboard
INSTRUMENT PANEL PIN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Specification GREY BODY: + Live GREY BODY: Right indicator control GREY BODY: * GREY BODY: High-beam lights input GREY BODY: * GREY BODY: Select 3 (Set) GREY BODY: Select 2 (Down) GREY BODY: Select 1 (Up) GREY BODY: Fuel reserve sensor GREY BODY: Ambient temperature sensor GREY BODY: + Battery GREY BODY: Left indicator control GREY BODY: Hazard control GREY BODY: * GREY BODY: * GREY BODY: Indicator reset GREY BODY: Oil sensor input GREY BODY: 750/1200 Selection GREY BODY: * GREY BODY: K Line BLACK BODY: + Battery BLACK BODY: Front left turn indicator activation BLACK BODY: Front right turn indicator activation BLACK BODY: Aerial 2 BLACK BODY: * BLACK BODY: CAN H BLACK BODY: CAN L BLACK BODY: ABS warning light input BLACK BODY: * BLACK BODY: Ground for sensors BLACK BODY: + Battery BLACK BODY: Rear left turn indicator activation BLACK BODY: Rear right turn indicator activation Desc./Quantity PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16 PIN 17 PIN 18 PIN 19 PIN 20 PIN 21 PIN 22 PIN 23 PIN 24 PIN 25 PIN 26 PIN 27 PIN 28 PIN 29 PIN 30 PIN 31 PIN 32 PIN 33
ELE SYS - 80
SL 750 SHIVER
Electrical system
34 35 36 37 38 39 40
NOTE
Specification BLACK BODY: Aerial 1 BLACK BODY: Light relay activation BLACK BODY: * BLACK BODY: * BLACK BODY: General ground BLACK BODY: General ground BLACK BODY: General ground
THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR.
Can line
CAN line Function It allows communication between the Marelli injection control unit, the throttle control unit and the instrument panel. Level in wiring diagram:CAN line Pin-out: see wiring diagram AXONE: ELECTRICAL ERRORS U1602 CAN line without signals - Bus Off. Error cause No communication on CAN line (PIN 20 and/or PIN 51 VEHICLE): problem on the whole network (for example, battery cut-off or short circuited or shorted to ground). Troubleshooting Check the Marelli control unit VEHICLE connector: if not OK, restore; if OK, check the earth insulation of the two CAN lines from PIN 20 and PIN 51 of the VEHICLE connector: If not OK, restore the cable harness; if OK, check continuity of the two CAN lines from the Marelli control unit VEHICLE connector to the filter casing large connector and to the instrument panel connector: if not OK, restore the cable harness; if OK, check that the two lines are not short circuited to positive testing each of the 3 connectors (Marelli control unit connector, filter casing large connector and instrument panel connector) with 1 connector disconnected at a time and by setting the key to ON: If not OK, restore; if OK, replace the Marelli control unit. Mute Node CAN Line, U1601 - Mute Node ELE SYS - 81
Electrical system
SL 750 SHIVER
Error cause The injection ECU cannot send CAN signals; it receives signals from the instrument panel and the throttle control unit: the control unit may need replacing. Troubleshooting Replace the Marelli control unit.
CAN line to instrument panel, U1701 - no signal Error cause No signal is received from the instrument panel.
Troubleshooting Check the connector of the instrument panel: if not OK, restore; if OK, check the continuity of the two lines from the instrument panel connector to the VEHICLE connector of the Marelli control unit: if not OK, restore the cable harness; if OK, replace the instrument panel. CAN line to the throttle control unit, U1705 - no signal Error cause No signal is received by the throttle control unit.
Troubleshooting Check the filter housing large connector and the throttle control unit connector: if not OK, restore; if OK, check the continuity of the two lines from the filter housing large connector to the VEHICLE connector of the Marelli control unit: if not OK, restore the cable harness; if OK, check the continuity of the two lines from the filter housing large connector to the throttle control unit connector: if not OK, restore the cable harness; if OK, replace the throttle control unit. AXONE: LOGIC ERRORS CAN Line to throttle control unit, U1706 - no message update. Error cause No updated signal is received from the throttle control unit.
ELE SYS - 82
INDEX OF TOPICS
ENG VE
SL 750 SHIVER
Vehicle preparation
Remove the air filter case. Remove the coolant radiator. Remove the exhaust system. Place the optional under-sump and rear wheel service stands. Undo and remove the screw and move the coil.
Disconnect the horn connectors. Disconnect the engine oil pressure sensor connector.
ENG VE - 2
SL 750 SHIVER
Undo and remove the screw and collect the washer. Disconnect the ground leads.
Undo and remove the three screws. Remove the clutch control cylinder. Lock the plunger using a clamp.
ENG VE - 3
SL 750 SHIVER
Undo and remove the two screws. Remove the chain guard.
CAUTION
Undo and remove the three screws fixing the chain guide. Remove the clutch pin.
UPON REFITTING, PROPERLY GREASE THE O-RING INDICATED WITH THE ARROW AND BE CAREFUL NOT TO PINCH IT.
ENG VE - 4
SL 750 SHIVER
Loosen the screw and slide off the gear transmission connecting rod keeping it linked to the gear shift lever through the rod.
Slacken the gearing chain tension. Undo and remove the screw; collect the washer and the spacer. Slide off the pinion from the chain and remove.
ENG VE - 5
SL 750 SHIVER
See also
Air box Removing the radiator
Working on the right side, slightly slide off the three bolts. Collect the spacers on the opposite side. Check the spacer sizes so as not to interchange them upon refitting. Slide off the three bolts completely and collect their washers.
See also
Vehicle preparation
SL 750 SHIVER
Working on the right side, insert the three bolts with their washers. Working on the right side, place the spacers on the three bolts between the engine block and the chassis.
CAUTION
THE SPACERS HAVE DIFFERENT SIZES. REFIT THEM IN THE SAME WAY THEY WERE BEFORE BEING REMOVED. Working from the left side, tighten the three nuts. Release the engine from the belt and the hoist. Refit the pinion and restore the gearing chain clearance. Reconnect the electric connections and clamp the cable harnesses. Carry out the vehicle preparation operations but in reverse order, restore the correct level of all fluids and carry out the adjustments that may be required.
See also
Vehicle preparation Adjusting
ENG VE - 7
SL 750 SHIVER
ENG VE - 8
INDEX OF TOPICS
ENGINE
ENG
Engine
SL 750 SHIVER
Gearbox Diagram
Key 1. Complete gear shaft and spring 2. Selector lock 3. Selector sprocket wheel 4. M5x16 Screw 5. Sprocket wheel pawl 6. Spring 7. Pin for spring 8. Tone wheel 9. Complete transmission gear shaft 10.Forks 11.Fork shaft 12.Spring 13.Pin for spring 14.Gear selector 15.Fork shaft 16.Fork
ENG - 2
SL 750 SHIVER
Engine
17.Gear selector drum 18.M8x1.25 threaded pin 19.Selector locking plate 20.Complete main gear shaft 21.TE flanged screw, M6x15 22.Complete index lever 23.Spring
Key: 1. Main gear shaft Z=14 2. 2nd gear on primary Z=17 3. 3rd - 4th gear on secondary Z=20/22 4. 5th gear on primary Z=23 5. 6th gear on primary Z=24 6. Thrust washer 7. Circlip 8. Thrust washer 9. Thrust washer
ENG - 3
Engine
SL 750 SHIVER
10.Circlip 11.Transmission shaft 12.1st gear on primary Z=36 13.2nd gear on secondary Z=32 14.3rd gear on secondary Z=30 15.4th gear on secondary Z=28 16.5th gear on secondary Z=26 17.6th gear on secondary Z=25 18.Thrust washer 19.Circlip 20.Thrust washer 21.Thrust washer 22.Thrust washer 23.Floating bushing 24.Floating bushing 25.Floating bushing
ENG - 4
SL 750 SHIVER
Engine
CAUTION
THE MAIN SHAFT FORK IS SMALLER THAN THOSE OF THE SECONDARY SHAFT. ALL THE SECONDARY SHAFT FORKS ARE THE SAME SIZE.
ENG - 5
Engine
SL 750 SHIVER
Refitting Repeat the removal operations but in reverse order, make sure that the shim washer is fitted to the secondary shaft.
See also
Splitting the crankcase halves
ENG - 6
SL 750 SHIVER
Engine
Pawl Make sure that both pawl tips run free, without jamming
Selector plate spring With a thickness gauge, check that the spring is not deformed by over-stretching.
Undo and remove the four screws and remove the starter motor.
ENG - 7
Engine
SL 750 SHIVER
Generator side
Key: 1. Complete starter motor 2. Complete torque limiter 3. Starting ring gear 4. Freewheel flange 5. Freewheel 6. Complete rotor 7. Complete stator 8. Flywheel cover gasket 9. Flywheel cover 10.TCEI low head screw M6x30 11.TBIC screw M5x12 12.TE flanged screw 13.Cap 14.Gasket 15.TCEI screw M6X18 16.Woodruff Key 17.TE flanged screw 18.Washer
ENG - 8
SL 750 SHIVER
Engine
19.Plate 20.TE flanged screw 21.NGK R CR7EK spark plug 22.Reference dowel 23.TE flanged screw
NOTE
Specific tooling
020712Y Handle for Flywheel cover removal
ENG - 9
Engine
SL 750 SHIVER
CAUTION
THE PICK-UP AND STATOR SHALL BE REMOVED SIMULTANEOUSLY AS THEY ARE PART OF THE SAME ELECTRICAL BRANCH.
Heat the magneto flywheel with the specific heater. Lock the flywheel using the specific tool and loosen the screw.
Specific tooling
020713Y Flywheel extractor
ENG - 10
SL 750 SHIVER
Engine
Screw the anticlockwise bolt of the special tool on the external body. Keeping the external body blocked and gripping the key, screw the anticlockwise bolt so as to remove the flywheel from the crankshaft.
Specific tooling
020713Y Flywheel extractor Unscrew and remove the anticlockwise bolt of the special tool from the external body. Undo the screw from the crankshaft.
Specific tooling
020713Y Flywheel extractor Remove the flywheel together with the freewheel.
Remove the start-up transmission gear. In case of malfunction, the start-up transmission gear cannot be overhauled. Therefore, the complete transmission gear should be replaced.
ENG - 11
Engine
SL 750 SHIVER
Freewheel removal
Heat the magneto flywheel with the specific heater. Undo and remove the six screws. Remove the freewheel from the magneto flywheel.
Insert the flywheel on the crankshaft. Screw the screw together with the washer but without tightening.
ENG - 12
SL 750 SHIVER
Engine
Place the appropriate tool for locking the flywheel. Locking the flywheel in position, using the specific tool, tighten the screw on the crankshaft.
Specific tooling
020713Y Flywheel extractor
Clutch side
Remove the water pump cover. Undo and remove the eleven screws working in a diagonal sequence. Collect the gasket.
ENG - 13
Engine
SL 750 SHIVER
It is advisable to remove only the clutch cover in order to replace the clutch discs. Should the complete clutch assembly be removed, remove the crankcase, clutch side. It is however possible to remove the complete clutch assembly by removing only the clutch cover. In this case carry out the following operations: measure the clutch bell protrusion from the crankcase before removal; during refitting, first check that the measurement has not changed, then tighten the clutch nut. If it has changed, rotate the crankshaft so that the oil pump control drive gear engages correctly with the oil pump driven gear on the clutch bell.
ENG - 14
SL 750 SHIVER
Engine
Key: 1. Complete clutch bell 2. Washer 3. Clutch hub 4. Clutch pressure plate 5. Clutch spring 6. Washer 7. TCEI screw M6 8. Spacer 9. Anti-juddering 10.Belleville spring 11.Anti-juddering 12.Nitrided driven disc 13.Lathed drive disc 14.Drive disc 15.Driven disc
ENG - 15
Engine
SL 750 SHIVER
Remove the clutch side crankcase half. Undo and remove the six screws by loosening them 1/4 of a turn at a time; operate in stages and diagonally, and collect the washers and the clutch springs.
Remove the discs. Remove the spacer and the belleville spring.
ENG - 16
SL 750 SHIVER
Engine
Specific tooling
9100896 Clutch bell locking tool
Unscrew and remove the clutch hub nut and collect the washer.
Collect the special washer between the clutch hub and the bell. Collect the clutch bell.
ENG - 17
Engine
SL 750 SHIVER
THE STEEL DISCS MUST SHOW NO SCORES OR TEMPERING COLOUR. Measure the thickness of the clutch discs at four positions, replace them if not complying with specifications. Thickness of nine drive discs: 2.5 mm (0.10 in). Driven disc thickness: 2.95 3.05 mm (0.116 0.120 in)
ENG - 18
SL 750 SHIVER
Engine
MUSHROOM VALVE CHECK Check if the valve slides freely, without jamming. Blow compressed air into the valve and check that the lubricating oil passage holes open.
UPON REFITTING, THE GEAR COLLAR MUST ALWAYS BE FACING THE CLUTCH BELL.
Remove the rotation locking pin from the oil pump control gear.
Check the clutch bell for damage and wear that may result in clutch irregular operation. Deburr the teeth or replace the bell. MAIN DRIVEN GEAR CHECK ENG - 19
Engine
SL 750 SHIVER
Check the main driven gear for damage and wear and, if necessary, replace the main transmission driving gear and the clutch bell all together. Make sure there is not excessive noise during operation; if necessary, replace the main transmission driving gear and the clutch bell all together.
ENG - 20
SL 750 SHIVER
Engine
Fit the clutch bell. Make sure that the oil pump control drive gear of the clutch bell engages correctly with the oil pump driven gear.
Place the special washer correctly between the clutch bell and the hub.
CAUTION
FIT THE SPECIAL WASHER WITH THE MACHINING FACING THE BELL
ENG - 21
Engine
SL 750 SHIVER
Fit the clutch cover. Check that the measurement has not changed compared with the one carried out upon removal; tighten the clutch nut afterwards. If it has changed, rotate the crankshaft so that the oil pump control drive gear engages correctly with the oil pump driven gear on the clutch bell.
Fit the washer and a new clutch hub nut. Tighten the clutch hub nut using the specific tool.
Specific tooling
9100896 Clutch bell locking tool
CAUTION
Insert the flat ring (1). Insert the cupped ring (2).
BE CAREFUL WITH THE CUPPED RING FITTING SIDE; THE RING CONE SHALL BE DIRECTED TOWARDS THE ENGINE. ENG - 22
SL 750 SHIVER
Engine
Fit the lathed driven disc (3). Fit the nitrided steel disc (4).
Fit the clutch discs. Start with the friction material discs and alternate with steel discs.
Position all friction material discs with their teeth aligned in one of the long slots of the clutch bell.
Fit the clutch springs. Fit the screw washers. Tighten the six screws operating in stages and diagonally.
ENG - 23
Engine
SL 750 SHIVER
THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. Remove the head cylinder unit. Undo and remove the screw on the inlet side.
ENG - 24
SL 750 SHIVER
Engine
See also
Removing the cylinder
Cylinder head
Key: 1. Complete cylinder head 2. Inlet valve 3. Outlet valve 4. External valve spring 5. Internal valve spring 6. Upper cap 7. Lower cap 8. Stud bolt M8X3X46
ENG - 25
Engine
SL 750 SHIVER
9. Stud bolt 10.Water pipe fitting 11.TBEI screw 12.Joint 13.O-ring 14.Flanged nut M8X1.25 15.Flanged nut 16.Valve sealing ring 17.TE flanged screw 18.Lock nut M10x1.25 19.Water Temperature Sensor 20.Threaded cap M6X10 21.Threaded cap 22.TE flanged screw 23.To radiator
First remove the rear head cover in order to remove the rear head camshafts. First remove the front head cover in order to remove the front head camshafts. Mark the head camshafts, the corresponding sprocket wheels and cam caps in order not to interchange them upon refitting. Undo and remove the eight cam cap screws working in a diagonal sequence and in stages.
ENG - 26
SL 750 SHIVER
Engine
Remove the cam cap carefully so as not to go through it and damage the seats of the calibrated dowels.
ENG - 27
Engine
SL 750 SHIVER
Compress the valve springs with the specific tightening bow and with the spring compressing tool.
Specific tooling
AP8140179 Valve spring compressor 020721Y Adaptor for valve removal
Release the valve springs. Remove the valve spring fittings plus the springs.
ENG - 28
SL 750 SHIVER
Engine
Valve check
CAUTION
REPLACE THE VALVES ONE AT A TIME. DO NOT MIX THE COMPONENTS. EACH VALVE MUST BE INSERTED IN ITS SEAT, MARKED BEFORE REMOVAL.
CAUTION
THE SEAT (1) ON THE VALVE HEAD CANNOT BE REGROUND. IF REQUIRED, REPLACE THE VALVE. GRINDING WITH ABRASIVE PASTE IS ALLOWED; VALVE STEM END REGRINDING IS NOT ALLOWED. ENG - 29
Engine
SL 750 SHIVER
Clean off any combustion residues from the valves. Check the seat (1) on the valve head with a ruler flush. The surface of the seat must not be concave; replace the valve if necessary. Check the clearance between the stem and the valve guide: inlet: 0.013 - 0.040 mm (0.00051 - 0.00157 in); limit: 0.080 mm (0.00315 in) outlet: 0.025 - 0.052 mm (0.00098 - 0.00205 in); limit: 0.100 mm (0.00394 in) Check the valve eccentricity: valve stem (3) maximum eccentricity allowed: 0.05 mm (0.00197 in) valve head (4) maximum eccentricity allowed: 0.05 mm (0.00197 in) Check that the fixing grooves (5) of the valve cotters are in proper conditions.
VALVE SPRINGS Carry out a measurement and a visual inspection of the valve springs for damage, distortion or loss of tension. Measure the spring length at release position. Valve springs: minimum wear limit (6) 42.5 mm (1.673 in). Valve springs: minimum wear limit (7) 38 mm (1.496 in).
CAUTION
Using a round scraper, clean off any carbon deposits in the combustion chamber.
DO NOT USE A POINTED INSTRUMENT TO AVOID DAMAGING OR SCRATCHING THE SPARK PLUG THREADS OR THE VALVE SEATS. Check the head for damage or scratches and replace it if necessary.
ENG - 30
SL 750 SHIVER
Engine
Check there are no mineral deposits or rust in the head water cooled jacket; clean off if required. Use a checking ruler and a thickness gauge positioned diagonally to the ruler to measure the cylinder head distortion.
Maximum cylinder head distortion: 0.03 mm (0.0012 in) Check that the tappet covers and the camshaft toothed wheel cover are not damaged or worn; replace the defective part(s).
See also
Timing
Timing
Key: 1. Camshaft - front inlet 2. Camshaft - front outlet 3. Axial restraint 4. Complete timing system gear 5. Complete front timing system gear 6. Complete rear timing system gear ENG - 31
Engine
SL 750 SHIVER
7. Shim washer 8. Right nut M15x1 9. Special screw 10.Safety washer 11.Sealing ring 12.Camshaft support 13.Torx screw M6X35 14.Timing system chain 15.Chain guide slider 16.Chain tightener rod 17.Camshaft - rear inlet 18.Camshaft - rear outlet 19.Left nut M15x1 20.Spacer screw
Undo and remove the two screws. Remove the chain tightener and collect the gasket.
ENG - 32
SL 750 SHIVER
Engine
Chain removal
Remove the chain tensioner. Remove the main pinion. Remove the movable chain slider and release the fixed chain slider from the clamp. Unscrew and remove the pin of the timing chain intermediate gear paying attention not to damage the O-ring. Collect the washer. Remove the timing chain intermediate gear.
NOTE
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
See also
Removing the chain sliders Removing the chain tensioner
ENG - 33
Engine
SL 750 SHIVER
REAR HEAD First remove the flywheel in order to remove the chain sliders from the front head. Undo and remove the movable chain tensioner pad screw. Slide it off from the head to remove it.
Undo and remove the fixed chain tensioner pad screw. First remove the head in order to remove it.
See also
Removing the chain tensioner ENG - 34
SL 750 SHIVER
Engine
Fit the chain tensioner body on the cylinder and insert a new paper gasket. Tighten the two screws to the prescribed torque.
Insert the spring and tighten the screw together with the washer.
Cam timing
ENG - 35
Engine
SL 750 SHIVER
Timing
Rotate the crankshaft until the front cylinder piston reaches the top dead centre. Lock the crankshaft with the specific special tool
Specific tooling
020720Y Timing tool If necessary, remove the timing system gears from the camshafts: Place the camshaft with the timing system gear on a vice and protect the cams of the camshaft adequately. Unscrew and remove the nut.
ANTICLOCKWISE NUT FOR BOTH REAR CYLINDER SHAFTS, AN ANTICLOCKWISE ARROW HAS BEEN PUNCHED ON IT. Collect the washer. Remove the timing system gear from the camshaft.
Clean gears surfaces (camshaft cone and gear cone) with: "System MC 217 spray metal cleaner". Pre-fit the gear on the camshaft, so that it can turn freely. Place the two camshafts in the head seats and align the two camshaft holes with the head holes.
Align the clearance recovery gear to the main timing system gear using the specific tool.
Specific tooling
020718Y Camshaft gear alignment pin
ENG - 36
SL 750 SHIVER
Engine
Using the specific template, check the correct position of the cams.
NOTE
USE OF THE TEMPLATE: THIS TOOL IS PLACED ON THE CAMS WITHOUT THE CAM CAPS, USING THE PROFILE MARKED WITH THE NUMBER OF THE CYLINDER BEING USED, WITH THE MARKINGS FACING THE FLYWHEEL SIDE.
NOTE
THE TEMPLATE IS NOT A TOOL DESIGNED FOR TIMING BUT FOR IDENTIFYING THE CORRECT DIRECTION FOR CAMSHAFT FITTING (THE SHAFTS MAY BE FITTED ROTATED BY 180 WITH REFERENCE TO THE CORRECT POSITION).
Specific tooling
020723Y Template for timing overhead camshafts
Place the cam cap. Pre-tighten the eight screws in the sequence indicated, to the prescribed torque.
Tighten the eight screws in the sequence indicated, to the prescribed torque.
Specific tooling
020719Y Timing pin
INSTALL THE CAMSHAFT TIGHTENING NUTS WITH THE MARK FACING UP. Pre-tighten the gear nut on the camshaft.
REFIT THE NUT WITH THE MACHINED SURFACE FACING THE GEAR (THE MATERIAL ACRONYM SHOULD BE VISIBLE).
Engine
SL 750 SHIVER
Remove the camshaft, lock it on a vice with aluminium jaws, then tighten it to the prescribed torque.
DO NOT TIGHTEN THE CAMSHAFT GEAR NUT TO THE ULTIMATE TIGHTENING TORQUE WITH THE SHAFT MOUNTED ON THE CYLINDER. THIS OPERATION WOULD IRRETRIEVABLY DAMAGE THE HEAD .
Specific tooling
020718Y Camshaft gear alignment pin Release the crankshaft from the specific special tool. Rotate the crankshaft in the riding direction until the rear cylinder piston reaches the top dead centre. Lock the crankshaft with the specific special tool. Carry out the timing operations performed for the front cylinder.
Specific tooling
020720Y Timing tool
Cylinder-piston assembly
ENG - 38
SL 750 SHIVER
Engine
Key: 1. Cylinder - Piston 2. Piston 3. Compression ring 4. Oil scraper ring 5. Oil scraper ring 6. Pin 7. Pin stop ring 8. Gasket 9. Plate 10.TE flanged screw 11.Complete chain tensioner 12.TE flanged screw 13.Head-cylinder gasket 14.11.8X10 Pin
ENG - 39
Engine
SL 750 SHIVER
Unscrew and remove the four nuts, working in a diagonal sequence and in stages.
Slide off the head-cylinder unit from the stud bolts. Remove the three fixing screws of the cylinder head to the discharge and intake sides.
See also
Chain removal
Lock the connecting rod using the specific tool. Slide off the pin and remove the piston.
Specific tooling
020716Y Connecting rod locking
ENG - 40
SL 750 SHIVER
Engine
FOR SAFETY REASONS COVER THE CRANKCASE WITH A CLEAN CLOTH SO THAT THE SEEGER RINGS DO NOT FALL INTO THE CRANKCASE.
Remove the top ring, the intermediate ring and the three oil scraper rings.
ENG - 41
Engine
SL 750 SHIVER
See also
Removing the cylinder head Removing the cylinder
IF THE GROOVES ON THE CYLINDER LINER ARE EVIDENT, REPLACE THE CYLINDER AND THE PISTON. Clean off lime scales on the cylinder cooling slots. Measure the cylinder bore at a distance of 10 - 43 - 90 mm (0.39 - 1.69 3.54 in) from the head coupling surface; the highest value should be considered to estimate wear limits. Cylinder bore "C": 92.000 mm (3.6220 - in) C= D1 or D2 max Cylindricity tolerance: 0.020 mm (0.00079 in) Replace the cylinder, the piston and the piston ring all together if not complying with specifications.
ENG - 42
SL 750 SHIVER
Engine
IT IS NOT POSSIBLE TO MEASURE THE GAP OF THE OIL SCRAPER RING END: IF CLEARANCE IS EXCESSIVE, REPLACE THE THREE PISTON RINGS. ENG - 43
Engine
SL 750 SHIVER
Piston ring end gap: Top ring: 0.25 - 0.40 mm (0.0079 - 0.0157 in) Intermediate ring: 0.35 - 0.55 mm (0.0138 0.0216 in) Oil scraper ring: 0.20 - 0.70 mm (0.0079 - 0.0276 in)
PIN Clean off combustion residues from the piston crown and from the area above the top ring. Check for cracks on the piston and for compression on the piston sliding surface (seizing); Replace the piston if required.
CAUTION
SMALL STRIATIONS ON THE PISTON LINER ARE ADMISSIBLE. Measure the pin outside diameter (a) and if not complying with specifications, replace the pin. Pin outside diameter: 22.00 - 21.97 mm (0.8661 - 0.8650 in) Limit: 21.96 mm (0.8646 in)
Measure the pin housing diameter (b) and replace the piston if not complying with specifications.
Pin housing diameter (b): 22.010 - 22.015 mm (0.8665 - 0.8667 in) Calculate the clearance between pin and pin hole and, if not complying with specifications, replace both pin and piston. Pin - piston clearance: C = b - a 0.010 - 0.045 mm (0.0004 - 0.0018 in) Limit: 0.060 mm (0.0024 in)
SL 750 SHIVER
Engine
Specification Piston - cylinder coupling Type B Piston - cylinder coupling Type C Piston - cylinder coupling Type D Fitting clearance
Desc./Quantity Piston: 91.933 - 91.940 mm (3.6217 - 3.6197 in) Cylinder: 91.997 - 92.004 mm (3.6219 - 3.6222 in) Piston: 91.940 - 91.947 mm (3.6197 - 3.6199 in) Cylinder: 92.004 - 92.011 mm (3.6222 - 3.6225 in) Piston: 91.947 - 91.954 mm (3.6199 - 3.6202 in) Cylinder: 92.011 - 92.018 mm (3.6225 - 3.6227 in) Piston: 91.954 - 91.961 mm (3.6202 - 3.6205 in) 0.050 - 0.064 mm (0.00197 - 0.00252 in)
Fit the oil scraper ring on the piston, with its opening facing the exhaust side.
Fit the remaining sealing rings on the piston with a 90 offset one from the other.
Place a new locking ring on the piston. Place the piston on the connecting rod and insert the pin.
Specific tooling
020717Y Piston ring driver Place a new locking ring on the piston in order to lock the pin.
Specific tooling
ENG - 45
Engine
SL 750 SHIVER
THE STUD BOLTS SHOULD BE FITTED SO THAT THEY PROTRUDE. DISTRIBUTE Loctite 270 (high-strength) ON THE THREAD AND SCREW THE STUD BOLT ON THE CRANKCASE UNTIL THEY PROTRUDE BY 137 mm (5.39 in), THEN MAKE SURE THE Loctite HAS SET. Insert a new cylinder base gasket, it should be as thick as the gasket previously removed: 0.40 - 0.50 - 0.60 mm (0.0157 - 0.0197 - 0.0236 in). The silicone side should be facing the crankcase.
CAUTION
IF THE ORIGINAL GASKET THICKNESS CANNOT BE CHECKED OR SHOULD THE CYLINDER BE REPLACED, REFER TO THE "BASE GASKET SELECTION" SECTION. Before fitting the cylinder, place the chain sliders and the timing chain on the crankshaft; fit the timing chain on the crankshaft from the base side.
NOTE
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW AIR INTO THE LUBRICATION DUCT AND LUBRICATE THE CYLINDER LINER.
Insert the cylinder-head unit on the stud bolts. Working in a diagonal sequence and in stages, screw the four nuts once the stud bolt threads have been greased.
ENG - 46
SL 750 SHIVER
Engine
Tighten the three screws on the intake and discharge sides. Screw the two head fixing screws located inside the timing chain compartment.
Check that the intermediate gear pin lubrication holes are clean.
With a hook, hold the timing chain. Fit the timing chain on the intermediate gear. Slide in the pin together with a new ORing and a washer.
ENG - 47
Engine
SL 750 SHIVER
Check that the axial clearance between the pin and the gear is between 0.30 and 0.60 mm (0.0118 - 0.0236 in).
Tighten the intermediate gear pin once Loctite residues are thoroughly removed and a high-strength threadlock is applied on the thread.
Make sure that both timing chain sliders are correctly fitted. Refit the overhead camshafts following the procedure described in the "Timing" section.
See also
Selecting the base gasket
Specific tooling
AP8140302 tool for sealing ring fitting
Temporarily, fit the piston to the cylinder, without base or head gasket. Remove the clamp from the sealing ring locking tool. Remove the special tool for locking the connecting rod.
ENG - 48
SL 750 SHIVER
Engine
Fit a dial gauge on the specific tool. Set the dial gauge to zero on a reference surface with a medium preload, e.g. 5 mm (0.2 in). Keeping the zero setting, fit the tool on the cylinder and lock it with two nuts (10 Nm - 7.38 lb ft) as shown in the figure.
Specific tooling
020714Y Comparator support Rotate the crankshaft up to the TDC (the reversal point of the dial gauge rotation). Lock the crankshaft at TDC using the specific tool. Calculate the difference between the two measurements: using the chart below, identify the thickness of the cylinder base gasket to be used upon refitting. By correctly identifying the cylinder base gasket thickness, an adequate compression ratio can be maintained Remove the specific tool and the cylinder.
Specific tooling
020720Y Timing tool
BASE GASKET
Specification Measured protrusion -0.10 / + 0.0 mm (- 0.0039 / 0.0000 in) Measured protrusion 0.05 / 0.10 mm (0.0020 / 0.0039 in) Measured protrusion 0.15 / 0.30 mm (0.0059 / 0.0118 in) Desc./Quantity Gasket 0.4 mm (0.0157 in) Gasket 0.5 mm (0.0197 in) Gasket 0.6 mm (0.0236 in)
ENG - 49
Engine
SL 750 SHIVER
Fit a new gasket between the cylinder and the head. Couple the cylinder and the head.
Screw without tightening the screw on the intake side. Tighten the cylinder-head fixing screws to the prescribed torque. Place the cylinder-head unit on the crankcase stud bolts.
BEFORE REFITTING HEAD COVERS, CLEAN HEAD AND COVER SURFACES CAREFULLY. ENG - 50
SL 750 SHIVER
Engine
Apply THREEBOND on the head cover perimeter along the gasket housing.
For the remaining operations, follow the removal operations but in reverse order.
Crankcase - crankshaft
Engine
SL 750 SHIVER
2. Lower bushing 3. Ball bearing 25x62x17 4. Ball bearing 30x62x23.8 5. Ball bearing 25x42x9 6. Ball bearing 20x47x14 7. Roller casing 30x37x12 8. Roller casing 9. Washer 10.TSPEI screw M6x12 11.Sealing ring 12.Sealing ring 8x16x7 13.Sealing ring 14x22x5 14.Sealing ring 20x30x5 15.Threaded cap 16.Oil spraying pipe 17.OR sealing ring 18.TCEI screw M5X16 19.Timing sensor 20.TE flanged screw 21.Seeger ring for hole 22.Special screw 23.Washer
Specific tooling
020711Y Engine pinion locking
ENG - 52
SL 750 SHIVER
Engine
ENG - 53
Engine
SL 750 SHIVER
Undo and remove the screw fixing the speed sensor. Carefully remove the speed sensor.
Undo and remove the three screws fixing the gear selector plate.
ENG - 54
SL 750 SHIVER
Engine
Undo and remove the two screws fixing the neutral sensor.
If the pinion has been removed, refit and lock it with a special tool.
Specific tooling
9100896 Clutch bell locking tool
ENG - 55
Engine
SL 750 SHIVER
The tone wheel is sealed with Loctite. Heat it with a suitable blower, paying special attention not to reach high temperatures. Remove the speed sensor catch with the specific special tool. Reposition the tone wheel and seal it with highstrength Loctite upon refitting.
Specific tooling
020715Y Tone wheel removal
ENG - 56
SL 750 SHIVER
Engine
Working on the left side, undo and remove the nine M8 screws fixing the crankcase.
Working on the left side, undo and remove the nine M6 screws fixing the crankcase.
ENG - 57
Engine
SL 750 SHIVER
CAUTION
UPON REFITTING THE FUEL BREATHER CLAMPING PLATE, REMEMBER TO INSTALL IT IN THE PINION AREA.
Rotate the engine and the engine support into horizontal position.
Undo and remove the pin, tighten it again one turn to allow for crankcase clearance and check sealing.
CAUTION
PAY SPECIAL ATTENTION TO ENGINE AND ENGINE SUPPORT STABILITY AND MAKE SURE THE ENGINE-TO-PLATE FIXING IS RELIABLE.
ENG - 58
SL 750 SHIVER
Engine
Separate the crankcase halves by giving a few taps with a rubber hammer.
ENG - 59
Engine
SL 750 SHIVER
If necessary, undo and remove the two screws fixing the strum box. Remove the strum box.
See also
Removing the cylinder Magneto flywheel removal Disassembling the clutch
Key: 1. Complete crankshaft 2. Complete connecting rod 3. Connecting rod screw 4. Bushing half-shell 5. Main transmission gear 6. Woodruff Key 7. Water pump gear
ENG - 60
SL 750 SHIVER
Engine
See also
Splitting the crankcase halves
TO AVOID DAMAGING BOTH CRANKCASE HALVES PLACE THEM ON A FLAT SURFACE. Check that both crankcase halves are not cracked or damaged. Check that all threads are in proper conditions. Check that all oil seals remaining in their position are not worn or damaged. Check all ball bearings for clearance, smoothness and potential distortions.
CAUTION
LUBRICATE BALL BEARINGS WITH ENGINE OIL BEFORE FURTHER CHECKING. If the internal ring does not rotate smoothly and silently or if there is some noise while it turns, it means that the bearing is faulty and must be replaced. OIL FILTER AND OIL DELIVERY PIPE CHECK Check the oil filter for damage. If necessary, replace the part. Clean the oil net with petrol and inspect the net links for potential damage.
ENG - 61
Engine
SL 750 SHIVER
LUBRICATION CHECK Working on both crankcase halves, remove and thoroughly clean the nozzle that lubricates the piston crown. REPLACE THE SPRAY NOZZLE O-RING IF NECESSARY.
Before refitting
UPON REFITTING THE CRANKSHAFT, GREASE THE SHAFT BUSHING-CONNECTING ROD COUPLING.
ENG - 62
SL 750 SHIVER
Engine
Specific tooling
020714Y Comparator support
TO FIT THE CONNECTING RODS, CHECK THE COUPLING TYPES INDICATED IN THE "CRANKCASE- CRANKSHAFT CONNECTING ROD" SECTION, IN THE "CHARACTERISTICS" CHAPTER OF THE WORKSHOP MANUAL.
ENG - 63
Engine
SL 750 SHIVER
CAUTION
Turn the engine support into horizontal position. Place the left crankcase half on the engine support, fitting it on the engine support pins.
PAY SPECIAL ATTENTION TO ENGINE AND ENGINE SUPPORT STABILITY AND MAKE SURE THE ENGINE-TO-PLATE FIXING IS RELIABLE. Fit the complete transmission gears unit. Apply black sealing paste (Threebond) on the left crankcase half.
CAUTION
BE CAREFUL NOT TO APPLY THREEBOND IN EXCESS AS IT MAY BLOCK OIL DUCTS THROUGH THE CRANKCASE HALVES.
Place the right crankcase half with the aid of a rubber hammer.
ENG - 64
SL 750 SHIVER
Engine
Rotate the engine and the engine support into vertical position. Working on the left side, place the nine M6 screws fixing the crankcase.
Working on the left side, place the nine M8 screws fixing the crankcase. Tighten all the crankcase fixing screws, both M6 and M8 type.
ENG - 65
Engine
SL 750 SHIVER
Place the gear selector drum and check that it is correctly timed; thrust the desmo drum axially from the flywheel side so that the timing roller protrudes.
ENG - 66
SL 750 SHIVER
Engine
Specific tooling
020715Y Tone wheel removal
Specific tooling
9100896 Clutch bell locking tool
ENG - 67
Engine
SL 750 SHIVER
Place the neutral sensor and lubricate its seat to facilitate refitting.
BE CAREFUL NOT TO DAMAGE THE O-RING WHEN INSERTING THE SENSOR IN ITS POSITION.
Tighten the three screws fixing the gear selector plate by applying Loctite medium-strength.
ENG - 68
SL 750 SHIVER
Engine
Place the speed sensor with caution. Tighten the speed sensor fixing screw.
Remove the grease off the primary pinion tapered pins - crankshaft coupling surfaces .
Fit the special tool and fix it steadfastly to the crankcase by tightening the four fixing screws on the crankcase.
Specific tooling
020711Y Engine pinion locking
ENG - 69
Engine
SL 750 SHIVER
ENG - 70
SL 750 SHIVER
Engine
Undo and remove the two screws fixing the oil pump.
Inspection
Undo and remove the two fixing screws.
ENG - 71
Engine
SL 750 SHIVER
Using a thickness gauge check clearance between rotor and stator and replace the rotor / stator unit if required.
clearance between rotor and stator: 0.04 0.10 mm (0.0016 in 0.0039 in)
ENG - 72
SL 750 SHIVER
Engine
CAUTION
CHECK THAT THE ROTOR AND STATOR ARE NOT DAMAGED (NO EVIDENT ABRASIONS, SCORES OR ANY OTHER MARKS).
Installing
Follow the oil pump removal operations; carefully align the stator and rotor references upon fitting and check clearance with a thickness gauge. If required, replace the stator / rotor unit.
ENG - 73
Engine
SL 750 SHIVER
ENG - 74
INDEX OF TOPICS
POWER SUPPLY
P SUPP
Power supply
SL 750 SHIVER
Fuel pump
Key: 1. Complete fuel pump unit 2. Lower self-locking nut M5 3. Brake pipe plate 4. Flange gasket 5. Fuel filter 6. Fuel delivery pipe Electrical characteristics: Resistance: 0.7 +/- 0.2 Ohm
AXONE: ELECTRICAL ERRORS Fuel pump relay control P0230 Example value: short circuit to positive / open circuit, short circuit to negative. Error cause If shorted to positive: excessive voltage has been detected at PIN 62 of the VEHICLE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 62 of the VEHICLE connector
P SUPP - 2
SL 750 SHIVER
Power supply
The functions required from the Marelli control unit therefore are: 1. Ride by Wire system control (throttle map) 2. Injection/ignition control 3. System safety checks 1 - Ride by Wire system control THROTTLE GRIP POSITION SENSOR The throttle grip is the part to which the throttle control cables arrive; its task is to translate the rider's power request into an electrical signal to be sent to the electronic control unit. The two throttle cables (opening and closing) actuate on a scroll mounted on a shaft and which is sent back to its home position by a return spring. On the shaft covers there are 2 double track potentiometers (4 control tracks) by means of which the torque demand is read (and checked). Marelli 5DM electronic control unit Besides the regular control functions of the injection system, it supervises the throttle bodies: Through the throttle grip position sensor, it reads the torque demand and, through the THROTTLE MAP, it decides the throttle opening and sends the command to the throttle valve control unit. It checks the correct operation of each component (Self-diagnosis), of the system (Safety), and carries out the emergency procedure (Recovery). EFI throttle control unit The control unit receives the target throttle opening to be carried out and it actuates on the control acting on the throttle body motors. It checks (through the throttle position sensor signal) that the throttle bodies have reached the target position. It communicates the position reached to the Marelli control unit. It does not actuate on Safety strategies. P SUPP - 3
Power supply
SL 750 SHIVER
Throttle Body The two throttle bodies are made up of: Throttle valve with 2 return springs for the controlled minimum opening position. DC electrical motor Tinned double throttle position sensors with magnetic control (contactless)
The throttle bodies do not require any maintenance and cannot be overhauled. In case of electric or mechanic malfunction, replace the whole unit. Pressure sensors The pressure sensors (one per cylinder) are fundamental not only for the injection map at low and stabilised speeds but also for checking the Ride by Wire system: their signal is connected to a TORQUE CHAIN for checking the correct opening of the throttle valves. Intake air temperature sensor The signal coming from the sensor is used to calculate the estimated torque since the oxygen in the air also depends on its density which varies according to temperature. 2 - Injection/ignition control Map for injection type (alpha-D)/rpm where: alpha is the throttle position D is the pressure measured at inlet ducts Rpm are the engine revolutions At idle and for slow and stabilised speeds D/n For medium-high throttle openings alpha/n For temporary speed (speed change) alpha/n The main parameters that correct the injection map are: Engine temperature Atmospheric pressure (calculated) Lambda probe signal Air temperature
3 - System safety checks The checks are structured in several levels: Level 1 - sensor correct operation Level 2 - comparison between requested torque and estimated torque generated by the engine Level 3 - a microprocessor controls the correct operation of the regular microprocessor
The consequent maintenance operations may be of different gravity according to the level and the defective component: A the malfunction does not affect riding in safety, the warning light turns on, the word Service is displayed, the signal recovery value considered not reliable is used and the engine works regularly. B the malfunction may affect riding in safety, the warning light turns on, the message Urgent Service is displayed, the torque demands are not fully activated (reduced torque). C the malfunction may affect riding in safety, the warning light turns on, the message Urgent Service is displayed, the engine operates in Limp Home function (accelerated idle), the throttles which are at P SUPP - 4
SL 750 SHIVER
Power supply
the position exclusively depending on the springs are not moved. The engine may shut off during the operation if it is running at idle speed and the gear is in neutral. D the malfunction may affect riding in safety, the warning light turns on, the message Urgent Service is displayed, the engine stops running.
UPON REFITTING , REPLACE THE THROTTLE BODY GASKET WITH A NEW ONE OF THE SAME TYPE.
P SUPP - 5
Power supply
SL 750 SHIVER
Working on both bodies, undo and remove the two plate screws.
Remove the plate. Working on both bodies, undo and remove the screw and detach the body.
Working on the body in question, remove the injector, slide off the clip and the injector itself.
CAUTION
P SUPP - 6
SL 750 SHIVER
Power supply
P SUPP - 7
Power supply
SL 750 SHIVER
P SUPP - 8
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
SL 750 SHIVER
Key: 1. Front wheel 3.5"x17" 2. Tubeless valve 3. Internal spacer 4. Bearing 5. Sealing ring 30x47x7 6. Seeger ring 7. Front wheel right external spacer 8. Front brake disc 9. Washer 25.2x36x1 10.Wheel pin nut 11.TE flanged screw M8x20 12.Front wheel pin 13.Front cover 120/70 ZR 17" Hold the scooter front part.
SUSP - 2
SL 750 SHIVER
Suspensions
Undo the screws fixing the front mudguard and remove it.
Undo the screws fixing the front pliers and slide them off the disc.
Remove the wheel pin fixing nut. Collect the sealing washer.
SUSP - 3
Suspensions
SL 750 SHIVER
Tap the wheel pin with a rubber hammer so that the holes on the opposite side are exposed.
Remove the wheel pin by inserting a screwdriver in the holes on the pin.
During extraction, support the wheel and then remove it. Collect the spacer from the front wheel left side.
CHECK THAT ALL THE PARTS ARE IN GOOD CONDITIONS, ESPECIALLY THOSE MENTIONED BELOW. ROTATION CHECK Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless. If one or both bearings do not fall within the control parameters: Replace both wheel bearings.
RADIAL AND AXIAL CLEARANCE CHECK Check the radial and axial clearance.
Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: Replace both wheel bearings.
SUSP - 4
SL 750 SHIVER
Suspensions
ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE. GASKETS Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive wear.
ALWAYS REPLACE BOTH GASKETS. ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE. WHEEL PIN Using a dial gauge, check the wheel pin eccentricity. If the eccentricity exceeds the limit value, replace the wheel pin.
Characteristic
Maximum eccentricity: 0.25 mm (0.0098 in) Using a dial gauge, check that the radial (A) and the axial (B) eccentricities of the rim do not exceed the limit value. An excessive eccentricity is usually caused by worn or damaged bearings. Replace the rim if, after replacing the bearings, the value is not within the specified limit.
Characteristic
Maximum radial and axial eccentricity: 2 mm (0.0079 in)
SUSP - 5
Suspensions
SL 750 SHIVER
Handlebar
Key: 1. Handlebar 2. Right light switch 3. Left light switch 4. Anti-vibration weight terminal 5. Anti-vibration weight 6. TCEI screw M6x40 7. Upper U-bolt 8. Screw M8x25 9. Handgrips 10.Right rear-view mirror 11.Left rear-view mirror 12.Throttle opening cable 13.Throttle closing cable
Front fork
SUSP - 6
SL 750 SHIVER
Suspensions
Diagram
Key: 1. Fork right stem 2. Fork left stem 3. Sleeve 4. Spring 5. Preloading pipe 6. Right pumping member assembly 7. Left pumping member assembly 8. Sleeve cap assembly 9. O-ring 10.Rubber ring 11.Nut 12.Snap ring 13.Stem+ right wheel holder assembly 14.Stem+ left wheel holder assembly 15.Dust guard 16.Seeger ring 17.Oil seal 18.Ring 19.Guide bushing
SUSP - 7
Suspensions
SL 750 SHIVER
20.Sliding bushing 21.Special washer 22.Screw M10x1.5 23.TE flanged screw M8x40 24.Spring Centring
Draining oil
NOTE
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS GET A CONTAINER WITH SUITABLE CAPACITY TO COLLECT THE OIL. Remove the fork.
SUSP - 8
SL 750 SHIVER
Suspensions
Being careful not to damage the fork stem when placing it in a vice, in vertical position, using the appropriate protection.
Specific tooling
AP8140149 Protection for fitting operations
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DISPOSE OF ENGINE OIL STORED IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL RECLAMATION FIRM.
See also
Removing the fork legs
DO NOT INTERCHANGE THE STEMS, THEY HAVE INTERNAL DIFFERENCES. THE LEFT CARTRIDGE (2) HAS A SLOT AT THE BOTTOM, WHILE THE RIGHT ONE (1), HAS A SLOT ON THE UPPER SIDE.
SUSP - 9
Suspensions
SL 750 SHIVER
NOTE
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS. Drain the fork oil. Place the fork stem on a work table in upright position. Fit the special tool.
Specific tooling
AP8140147 Spacer tool
With the help of a second operator: Hold the sleeve cap firmly. Push the special tool down. Take out the Seeger ring.
SUSP - 10
SL 750 SHIVER
Suspensions
With the help of a second operator: Insert the special tool between the nut and the preloading pipe.
Specific tooling
AP8140148 Spacer-pumping element separating plate
Slide off the preloading pipe together with the spring centring.
SUSP - 11
Suspensions
SL 750 SHIVER
Be careful not to damage the fork stem when placing it in a vice, in horizontal position, using the appropriate protections.
Specific tooling
AP8140149 Protection for fitting operations
Unscrew and remove the bottom screw and collect the special washer.
SUSP - 12
SL 750 SHIVER
Suspensions
Remove the Seeger ring from inside the sleeve with the aid of a screwdriver.
CAUTION
If necessary, remove the sliding bushing, guide bushing, ring, oil seal, Seeger ring and dust guard from the stem.
See also
Draining oil
A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.
Characteristic
SUSP - 13
Suspensions
SL 750 SHIVER
Bending limit: 0.2 mm (0.00787 in) Sleeve Check that there are no damages and/or cracks; otherwise, replace it. Spring Check that the spring is in good conditions. Check that the spring length is within the limit value. Replace the spring if its length does not fall within the limit values. SPRING MINIMUM LENGTH WHEN UNLOADED: 300.8 mm (11.84 in) Check that the following components are in good conditions: sliding bushing; guide bushing;
pumping member.
If there are signs of excessive wear or damage, replace the affected component.
CAUTION
REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SURFACE. Replace the following components with new ones: oil seal dust guard
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS. Fit the dust guard (1), Seeger ring (2), oil seal (3), ring (4), guide bushing (5) and sliding bushing (6) on the stem.
CAUTION
FIT THE GUIDE BUSHING AND THE SLIDING BUSHING WITH CAUTION. GUIDE BUSHING (5) IS THICKER THAN SLIDING BUSHING (6).
SUSP - 14
SL 750 SHIVER
Suspensions
Fit the stem to the sleeve and place the special fitting tool for fitting the D.43 oil seal between the Seeger ring and the oil seal.
Specific tooling
AP8140189 Oil seal fitting tool for 43 mm (1.69 in) holes
Push the oil seal fitting special tool hard, applied towards the sleeve with the aid of the specific weight.
Specific tooling
AP8140146 Weight
SUSP - 15
Suspensions
SL 750 SHIVER
Screw the specific perforated rod on the pumping member threaded rod.
Specific tooling
AP8140150 Perforated rod for pumping member air bleed
Fit the centring plate. Fit the pumping member together with the centring plate in the sleeve. Insert the special washer in the screw. Tighten the screw to the prescribed torque.
Filling oil
NOTE
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS. Place the fork stem on a work table in upright position. Fill the sleeve with the adequate quality and type of oil indicated on the recommended products table.
WARNING
MOVE THE PUMPING ELEMENT SEVERAL TIMES UNTIL AIR BUBBLES ARE SEEN ON THE OIL SURFACE.
THE SLEEVE MUST BE PERFECTLY VERTICAL FOR A CORRECT OIL LEVEL MEASUREMENT. THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS.
Characteristic
Fork oil quantity (for each stem): 535 cm (32.65 cu.in)
SUSP - 16
SL 750 SHIVER
Suspensions
Oil level (from sleeve rim, without the spring and with pumping member fully down) 122 mm (4.80 in). Fit the spring.
Specific tooling
AP8140147 Spacer tool
With the aid of a second operator, hold the pumping member rod firmly, lower the spacer retention tool, insert the stop ring and the plate separating the spacer-pumping member between the ring and the nut.
Specific tooling
AP8140148 Spacer-pumping element separating plate
SUSP - 17
Suspensions
SL 750 SHIVER
Being careful not to damage the fork stem when placing it in a vice, in vertical position, using the appropriate protection.
Specific tooling
AP8140149 Protection for fitting operations
SUSP - 18
SL 750 SHIVER
Suspensions
Steering bearing
Key: 1. Folk lower plate 2. Screw M8x30 3. Washer 4. Roller bearing 5. Sealing ring 6. Ring nut 7. Headstock cap washer 8. Headstock cap 9. TCEI screw M10x60 10.Cap 11.Rubber ring 12.Lower U-bolt 13.Fork upper plate 14.Screw M8x30 15.Spacer 10.1x14.1x38
Adjusting play
Place the vehicle so that the front wheel is off the ground. Shake the fork in the riding direction. SUSP - 19
Suspensions
SL 750 SHIVER
Adjust if clearance is detected. Unscrew and remove the four screws of the fixing U-bolt. Remove the U-bolt. Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out.
Unscrew and remove the top bolt on the headstock and collect the washer.
Operating from both sides, loosen the screws fixing the fork stems to the upper plate.
SUSP - 20
SL 750 SHIVER
Suspensions
Undo and remove the two screws fixing the instrument panel support to the fork upper plate.
Slide off the fork upper plate by moving it towards the instrument panel.
Adjust the steering bearings preloading by tightening the ring nut with the specific tool.
When refitting the U-bolt, position the two references facing the front part of the vehicle.
Rear
SUSP - 21
Suspensions
SL 750 SHIVER
Key: 1. Chain with master link 2. Crown 3. Rear wheel 6"x17" 4. Rear wheel anti-vibration buffer 5. Rear cover 180/55 ZR 17" 6. Anti-vibration rubber buffer 7. Tubeless valve 8. Rear wheel spacer 9. Pin 10.Lower self-locking nut M10 11.Sprocket carrier assembly 12.Anti-vibration buffer spacer 13.Bearing 30x55x13 14.Seeger ring for hole 15.Sealing ring 30x52x7 16.Internal spacer 17.Seeger ring 18.10x20 Pin 19.Bearing
SUSP - 22
SL 750 SHIVER
Suspensions
20.TCEI screw M10x30 21.Sealing ring 38x52x7 22.Master link Place the vehicle on its rear service stand. In order to work faster, remove that the chain cover. Fully slacken the gearing chain tension. Make the wheel move forward and release the gearing chain from the crown gear. Unscrew and remove the nut on the wheel pin. Collect the thrust washer and the right chain tensioner slider.
Working on the right side, hit the wheel pin lightly so as to take out the head from its housing.
Working on the left side, slide off the wheel pin together with the chain guide slider.
Remove the wheel by freeing the disc from the brake calliper.
SUSP - 23
Suspensions
SL 750 SHIVER
Working from the left side, unscrew and remove the five nuts and remove the crown and the bolts.
Undo and remove the five screws and remove the anti-vibration buffer holder. Check the anti-vibration buffers according to the routine maintenance table.
See also
Adjusting
CHECK THAT ALL THE PARTS ARE IN GOOD CONDITIONS, ESPECIALLY THOSE MENTIONED BELOW. REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel. ROTATION CHECK Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless. If one or both bearings do not fall within the control parameters: SUSP - 24
SL 750 SHIVER
Suspensions
ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE. Check the radial and axial clearance.
Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: Replace both wheel bearings.
REAR WHEEL GASKETS Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive wear.
ALWAYS REPLACE BOTH GASKETS. ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE. REAR WHEEL PIN Using a dial gauge, check the wheel pin eccentricity (1). If the eccentricity exceeds the limit value, replace the wheel pin (1).
Characteristic
Maximum eccentricity: 0.25 mm (0.0098 in) REAR WHEEL RIM Using a dial gauge, check that the radial (A) and the axial eccentricity (B) of the rim (2) do not exceed the limit value. An excessive eccentricity is usually caused by worn or damaged bearings. Replace the rim (2) if after replacing the bearings, the value is not within the specified limit.
Characteristic
Maximum radial and axial eccentricity: 2 mm (0.0079 in)
SUSP - 25
Suspensions
SL 750 SHIVER
Loosen the under-sump optional service stand to lower the engine. Undo and remove the lower screw and collect the nut. Remove the shock absorber.
SUSP - 26
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
SL 750 SHIVER
Swinging arm
Key: 1. Swingarm 2. Roller casing 3. Ball bearing 4. Internal spacer 5. Sealing ring 6. Seeger ring for hole 7. O-ring 8. Sealing ring 9. Swing arm pin 10.Adjustment bushing 11.Swingarm pin internal bushing 12.Swingarm pin ring nut 13.Rear wheel bolt nut 14.Rear wheel pin washer 15.Left chain guide slider 16.Right chain guide slider 17.Chain tensioner set screw 18.Serpress nut M8
CHAS - 2
SL 750 SHIVER
Chassis
19.Rear stand bushing 20.TSPEI screw M6x40 21.Chain guide slider 22.TBEI screw M5x12 10.9 23.Slider cap 24.Chain guard 25.TBEI special screw M5x12 26.Rear wheel pin 27.Washer 25.2x36x1 28.Wheel bolt nut M25x1.5 29.Counterslider 30.TBEI special screw M5x12
Removing
Remove the rear wheel. Support the vehicle by means of the engine service stand and a hoist with belts fastened to the rear section of the frame. Remove the rear service stand. Undo and remove the two lower swingarm screws. Remove the cable guide. Slide off the rear calliper holding plate, keeping it linked to the brake pipe.
CAUTION
DO NOT ACTUATE ON THE REAR BRAKE LEVER AFTER REMOVING THE WHEEL. OTHERWISE, THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEAT, RESULTING IN BRAKE FLUID LEAKAGE.
CHAS - 3
Chassis
SL 750 SHIVER
With the specific box-spanner, unscrew and remove the locking ring nut.
Working from the left side, unscrew and remove the nut and collect the washer.
REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION. SUPPORT THE SWINGARM FROM THE FRONT TO AVOID ACCIDENTAL FALLS. PLACE A WOODEN SUPPORT UNDER THE FRONT PART OF THE REAR SWINGARM TO PREVENT IT FROM LOWERING AND TO KEEP IT UPRIGHT. Working on the right side, unscrew and remove the swingarm bolt.
UPON REMOVING THE REAR SWINGARM PAY ATTENTION NOT TO JAM THE GEARING CHAIN.
See also
Removing the rear wheel
CHAS - 4
SL 750 SHIVER
Chassis
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING APPLICATIONS. CLEARANCE CHECK To check the backlash: Shut off the engine. Place the vehicle on the service stand. Engage neutral gear. Check that at a point between the pinion and the crown on the lower branch of the chain the vertical oscillation is around 25 mm (0.98 in). Move the vehicle forward so as to check vertical oscillation in other positions too. backlash should remain constant during all wheel rotation phases. ADJUSTMENT
CAUTION
TO ADJUST THE CHAIN, GET THE APPROPRIATE REAR SERVICE STAND (OPT). If you need to adjust chain tension after the check: Place the vehicle on its OPTIONAL rear service stand. Loosen the nut (1) completely. Loosen both lock nuts (4). Actuate on the set screws (5) and adjust the chain backlash checking that the references (2 - 3) match on both sides of the vehicle.
CAUTION
Tighten both lock nuts (4). Tighten the nut (1). Check chain backlash.
WHEEL CENTRING IS CARRIED OUT BY USING THE FIXED REFERENCES (2-3) WITHIN CHAS - 5
Chassis
SL 750 SHIVER
THE SEATS OF THE CHAIN TENSIONER PADS ON THE SWING ARMS, IN FRONT OF THE WHEEL PIN.
CHECKING THE CHAIN, THE PINION AND THE CROWN FOR WEAR Furthermore, check the following parts and make sure the chain, the pinion and the crown do not show: damaged rollers; loosened pins; dry, rusty, flattened or jammed chain links; excessive wear; missing sealing rings; excessively worn or damaged pinion or crown teeth.
IF THE CHAIN ROLLERS ARE DAMAGED, THE PINS ARE LOOSE AND/OR THE O-RINGS ARE MISSING OR DAMAGED, THE WHOLE CHAIN UNIT (PINION, CROWN AND CHAIN) SHOULD BE REPLACED. LUBRICATE THE CHAIN ON A REGULAR BASIS, PARTICULARLY IF YOU DETECT DRY OR RUSTY PARTS. FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATING CONDITIONS RESTORED.
THE GEARING CHAIN HAS SEALING RINGS AMONG THE LINKS THAT KEEP THE GREASE INSIDE. ADJUST, LUBRICATE, WASH AND REPLACE THE CHAIN WITH UTMOST CAUTION. CLEANING AND LUBRICATION Do not wash the chain with water jets, steam jets, high-pressure water jets and highly flammable solvents. Wash the chain with fuel oil or kerosene. Maintenance operations should be more frequent if there are signs of quick rust. Lubricate the chain at the intervals specified on the routine maintenance table and whenever necessary. After washing and drying the chain, lubricate it with spray grease for sealed chains.
CHAS - 6
SL 750 SHIVER
Chassis
Exhaust
Key: 1. Central exhaust manifold 2. Rear main exhaust manifold 3. Front main exhaust manifold 4. Self-locking nut M8 5. Head exhaust gasket 6. Manifold exhaust gasket 7. Manifold clamp 8. Silencer 9. Silencer gasket 10.Silencer clamp 11.Lambda probe 12.TE flanged screw M8 x 35 13.Spacer bushing 14.Retroreflector supporting rubber ring 15.Washer 16.Muffler fixing rubber ring
CHAS - 7
Chassis
SL 750 SHIVER
Protect the swingarm so as not to spoil it while removing the exhaust end. Keeping the plastic cover up, undo and remove the two central screws and collect the washers.
CHAS - 8
SL 750 SHIVER
Chassis
See also
Removing the exhaust manifold
CHAS - 9
Chassis
SL 750 SHIVER
REAR Loosen the exhaust pipe between the manifold and the exhaust end. Unscrew and remove the two nuts on the head exhaust stud bolts.
See also
Removing the manifold - tail pipe
CHAS - 10
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
SL 750 SHIVER
Interventions rules
CAUTION
THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM.
Key: 1. Brake pump together with reservoir 2. Rear brake calliper 3. Rear brake lever 4. Rear brake lever pin 5. O-ring 6. Washer 10.5x21x2 7. Brake lever pin 8. Rubber ring for lever 9. Seeger ring 10.Spring retaining pin 11.Rear brake lever spring 12.Micro-switch 13.Fork Nut M6 14.Clips for gear fork
BRAK SYS - 2
SL 750 SHIVER
Braking system
15.TCEI screw M6x16 16.TE flanged screw M6x16 17.Flanged self- locking nut M6 18.TE flanged screw M6x20 19.Rear brake pipe 20.Brake plate stop pin 21.Oil pipe screw 22.Washer 10x14x1.6 23.Brake pipe protection 24.TBEI flanged screw M5x9 25.Rear brake pads - pair 26.Screws + Calliper springs 27.Air bleed 28.Oil reservoir assembly 29.REAR BRAKE DISC 30.TE flanged screw M8x20 31.O-ring
BRAK SYS - 3
Braking system
SL 750 SHIVER
2. Front brake calliper 3. Front brake pads - pair 4. Pin + calliper spring 5. Bleeding Kit 6. TE flanged screw M10x1.25x55 7. Copper washer
CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
BRAK SYS - 4
SL 750 SHIVER
Braking system
Removal
Remove the safety circlip.
CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO THE REGULAR USE CONDITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
NOTE
BRAK SYS - 5
Braking system
SL 750 SHIVER
THE FOLLOWING OPERATIONS REFER TO ONLY ONE FRONT BRAKE CALLIPER BUT APPLY TO BOTH CALLIPERS. THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. Remove the rubber protection cover from the bleed valve. Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a container to collect the fluid. Remove the front brake oil reservoir cap. Quickly press and release the front brake lever several times and then keep it fully pressed. Loosen the bleed valve 1/4 of a turn so that the brake fluid flows into the container. This will release the tension on the brake lever and will make it reach the end of stroke. Close the bleed valve before the lever reaches its end of stroke. Repeat the operation until the fluid draining into the container is air-bubble free.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. Screw the bleed valve and remove the pipe. Top-up the reservoir until the correct brake fluid level is obtained. Refit and block the front brake oil reservoir cap. Refit the rubber protection cover.
Rear
If there is air in the hydraulic system, it acts as a bearing, absorbing a large part of the pressure from the brake pump and minimising calliper efficiency during braking. The presence of air is signalled by the "sponginess" of the brake control and poor braking efficiency. BRAK SYS - 6
SL 750 SHIVER
Braking system
CAUTION
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CONDITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED. THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. Remove the rubber protection cover from the bleed valve. Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe into a container to collect the fluid. Remove the rear brake oil reservoir cap. Quickly press and release the rear brake lever several times and then keep it fully pressed. Loosen the bleed valve 1/4 of a turn so that the brake fluid flows into the container. This will release the tension on the brake lever and will make it reach the end of stroke. Close the bleed valve before the lever reaches its end of stroke. Repeat the operation until the fluid draining into the container is air-bubble free.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. Screw the bleed valve and remove the pipe. Top-up the reservoir until the right brake fluid level is obtained. Refit and lock the rear brake oil reservoir cap. Refit the rubber protection cover.
BRAK SYS - 7
Braking system
SL 750 SHIVER
BRAK SYS - 8
INDEX OF TOPICS
CLUTCH SYSTEM
CLU SYS
Clutch system
SL 750 SHIVER
Key: 1. Clutch pump 2. Clutch lever 3. Cover 4. U-bolt 5. Clutch pipe 6. Oil pipe screw 7. Washer 10x14x1.6 8. Clutch control cylinder 9. Bleeding Kit 10.TSPEI screw 11.TSPEI screw 12.Stop switch 13.Rubber ring
CAUTION
IF CLUTCH LEVER TRAVEL OR CLUTCH DISENGAGEMENT ARE IRREGULAR, CHECK THE CLUTCH SYSTEM FOR AIR BUBBLES AND BLEED THE SYSTEM THROUGH VALVE (9).
CLU SYS - 2
INDEX OF TOPICS
COOLING SYSTEM
COOL SYS
Cooling system
SL 750 SHIVER
Circuit diagram
Key: 1. Radiator 2. Opening 3. Cap 4. Expansion tank 5. Expansion tank cap 6. Water pipe 7. Thermostat-radiator pipe 8. Radiator-pump pipe 9. Radiator filling pipe 10.Bleed pipe 11.Valve-motor pump pipe 12.Bleed pipe 13.Y-shape coupling 14.Oil pipe 6x12 15.Oil pipe 6x12 16.Thermostat-valve unit 85 C (185 F) 17.Pin 18.Spacer
COOL SYS - 2
SL 750 SHIVER
Cooling system
19.Fan assembly 20.TCB screw 4.2x22 21.Washer 5.3x10x1 22.Front headlamp set spring 23.Rubber ring 10x20x10 24.Clic clamp 25.Clic clamp 26.Pipe clamp 27.TE flanged screw M6x25 28.TE flanged screw M6x20 29.Fuel pipe 5.5x10 30.Radiator support 31.Clic clamp 32.From front cylinder 33.From rear cylinder 34.To rear cylinder
Electric fan
Remove the radiator Undo and remove the three screws and collect the washers; remove the electric fan.
See also
Removing the radiator
COOL SYS - 3
Cooling system
SL 750 SHIVER
Coolant replacement
Remove the right side fairing. Undo and remove the screw and remove the protection.
Place a container of suitable capacity. Loosen the screw, move the clamp and slide off the sleeve.
Empty the system into the specific container. Loosen the screw and move the clamp.
COOL SYS - 4
SL 750 SHIVER
Cooling system
Refit both sleeves, place the corresponding clamps and tighten their screws. Fill the expansion tank up to the marked level. After bleeding the air from the tank, place the expansion tank cap. Refit the front protection and tighten the screw. Fit the right side fairing.
PUMP ROTOR REMOVAL Remove the clutch-side cover. Lock the pump shaft with a universal wrench on the hexagonal insert on the shaft. Unscrew and remove the anticlockwise nut fixing the rotor. Remove the rotor.
COOL SYS - 5
Cooling system
SL 750 SHIVER
Unscrew and remove the rotor control gear fixing nut and act on the gear hexagonal insert.
Remove the rotor control gear. From the cover inside to the outside, remove the rotor control shaft with a punch and a rubber hammer.
REFITTING Upon refitting, carry out the removal operations but in reverse order. From the outside to the inside, fit the rotor shaft plus the seal in the corresponding hole on the cover.
Drive the shaft plus the seal on the cover using the specific tool and a hydraulic press.
Refill the expansion tank so that the level is between the MAX and MIN marks. Fill the system through the radiator cap.
COOL SYS - 6
SL 750 SHIVER
Cooling system
Place the radiator cap on its seat (to avoid accidental leaks) but do not screw it and start the engine. Remove the radiator cap and refill until the radiator plates are completely covered and the water jet from the system breather pipe is continuous.
COOL SYS - 7
Cooling system
SL 750 SHIVER
Lower the radiator from the upper fixing side to the chassis and remove it by sliding it off toward the vehicle righthand side.
To install the radiator, follow the operations explained above but in reverse order, and replace all the clamps removed. Restore the correct coolant level.
See also
Coolant replacement COOL SYS - 8
SL 750 SHIVER
Cooling system
Undo and remove the screw and collect the washer. Slide off the expansion tank.
Thermostatic valve
Traditional circuit, three-way thermostatic valve: 1. Hot water inlet from the heads. 2. Outlet towards the short circuit (direct to the pump). 3. Outlet towards the radiator
COOL SYS - 9
Cooling system
SL 750 SHIVER
COOL SYS - 10
INDEX OF TOPICS
BODYWORK
BODYW
Bodywork
SL 750 SHIVER
Seat
SADDLE REMOVAL Place the vehicle on the service stand. Insert the key (1) in the lock. Turn the key (1) anticlockwise Paying attention to the belt position, release and lift the saddle (2). SADDLE LOCK Insert the bottom front lugs under the rear frame pin. Paying attention to the belt position, set the saddle (2) in its position and push, until it clicks shut.
CAUTION
BEFORE LOWERING AND LOCKING THE SADDLE, CHECK THAT THE KEY HAS NOT BEEN LEFT INSIDE THE GLOVE-BOX / TOOLKIT COMPARTMENT.
Headlight assy.
Remove the instrument panel. Working from the vehicle left side, unscrew and remove the pin, and collect the nut and the washer from the right side.
BODYW - 2
SL 750 SHIVER
Bodywork
Disconnect the front headlight connector and remove the front headlight assembly.
See also
Instrument cluster support
Taillight assy.
Remove the tail section. Undo and remove the screw. Collect the washer.
See also
Tail guard
BODYW - 3
Bodywork
SL 750 SHIVER
BODYW - 4
SL 750 SHIVER
Bodywork
LOWER SIDE FAIRINGS Remove the side fairing and afterwards remove the saddle. Undo and remove the two screws.
See also
Seat
BODYW - 5
Bodywork
SL 750 SHIVER
Undo and remove the two screws; collect the spacers and the collars.
See also
Seat Tail guard
Air box
Undo and remove the eight screws and remove the air filter.
BODYW - 6
SL 750 SHIVER
Bodywork
BODYW - 7
Bodywork
SL 750 SHIVER
Working from the left side, undo and remove the screw to remove the cable guide.
Undo and remove the two screws after loosening the front and rear manifold clamps.
BODYW - 8
SL 750 SHIVER
Bodywork
Lift the filter casing and working on both cylinders, loosen and move the clamp and slide off the oil vapour recovery pipe.
Working on the left side, disconnect the two control unit connectors.
CAUTION
THE CONNECTORS ARE MARKED BY THE LETTERS "V" (VEHICLE) AND "E" (ENGINE). DO NOT INTERCHANGE THEM WHEN REFITTING.
Undo and remove the screw and remove the ground lead.
BODYW - 9
Bodywork
SL 750 SHIVER
Remove the filter casing together with the throttle body, by lifting it up from behind.
CAUTION
Should the throttle body be removed, disconnect either the map sensor pipes or the inlet ducts; it is necessary to check the air system tightness. Using Axone, check the following parameters: a - take the vehicle temperature to 90 C (194 F) or above. b - front cylinder throttle valve correction between - 60 and 60. b - rear cylinder throttle valve correction between - 60 and 60. c - potentiometer 1 front throttle valve value is 0.5 or above. d - potentiometer 1 rear throttle valve value is 0.5 or above. e - the difference of throttle valve correction values between the front and rear cylinders should not exceed 0.6.
See also
Air filter
Fuel tank
Remove the saddle. Remove the side fairings.
BODYW - 10
SL 750 SHIVER
Bodywork
Remove at least one side air deflector. Slide off the key lock plate.
Undo and remove the two screws and collect the two collars. Undo and remove the chamber fixing screws. Slide off the "too full" and breather pipes from the chamber. Lift the tank by turning it on the hinge. Release the petrol pipe. Disconnect the pump cable harness. Working on the right side, unscrew and remove the nut and slide off the bolt from the left side.
BODYW - 11
Bodywork
SL 750 SHIVER
Protecting the vehicle from potential fuel leaks with a cloth, disconnect the quick coupler.
NOTE
UPON REFITTING THE TANK, KEEP THE FUEL PIPE CONNECTING THE PETROL PUMP TO THE FILTER HOUSING IN THE POSITION INDICATED BY THE FIGURE.
Front mudguard
Operating from both sides, undo and remove the two screws. Remove the front mudguard.
BODYW - 12
SL 750 SHIVER
Bodywork
Working on both sides, loosen the nut and the screw and remove them.
Working from both sides, tilting the front headlight forward, undo and remove the screw and collect the nut.
BODYW - 13
Bodywork
SL 750 SHIVER
Working on the back of the instrument panel, undo and remove the two screws and collect the two washers.
Disconnect the instrument panel connector. Remove the clamp and disconnect the air temperature sensor.
Tail guard
Working from both sides of the vehicle, undo and remove the screw and remove the lateral air intake.
BODYW - 14
SL 750 SHIVER
Bodywork
Operating from both sides of the vehicle, undo and remove the two screws.
Operating from both sides of the vehicle, undo and remove the screw.
Undo and remove the two screws and remove the rear light cover.
BODYW - 15
Bodywork
SL 750 SHIVER
BODYW - 16
SL 750 SHIVER
Bodywork
Operating from both sides, slide the exhaust cover tail upward and off.
Working on the right side, remove the right tail. Working on the left side, remove the saddle lock and the left tail.
BODYW - 17